Classifications

• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
  • C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
  • C08J9/16—Making expandable particles
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
  • B29B9/00—Making granules
  • B29B9/02—Making granules by dividing preformed material
  • B29B9/06—Making granules by dividing preformed material in the form of filamentary material, e.g. combined with extrusion
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
  • B29B9/00—Making granules
  • B29B9/02—Making granules by dividing preformed material
  • B29B9/06—Making granules by dividing preformed material in the form of filamentary material, e.g. combined with extrusion
  • B29B9/065—Making granules by dividing preformed material in the form of filamentary material, e.g. combined with extrusion under-water, e.g. underwater pelletizers
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
  • B29B9/00—Making granules
  • B29B9/10—Making granules by moulding the material, i.e. treating it in the molten state
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
  • B29B9/00—Making granules
  • B29B9/12—Making granules characterised by structure or composition
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
  • B29B9/00—Making granules
  • B29B9/16—Auxiliary treatment of granules
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
  • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
  • B29C44/34—Auxiliary operations
  • B29C44/3461—Making or treating expandable particles
• • 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
  • B32B15/00—Layered products comprising a layer of metal
  • 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
• • 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
  • 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
  • B32B21/047—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 foam
• • 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
  • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
  • B32B5/20—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material foamed in situ
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
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  • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
  • B32B7/04—Interconnection of layers
  • B32B7/08—Interconnection of layers by mechanical means
  • B32B7/09—Interconnection of layers by mechanical means by stitching, needling or sewing
• • B—PERFORMING OPERATIONS; TRANSPORTING
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  • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
  • B32B7/04—Interconnection of layers
  • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
  • C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
  • C08J9/04—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
  • C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
  • C08J9/16—Making expandable particles
  • C08J9/18—Making expandable particles by impregnating polymer particles with the blowing agent
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
  • C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
  • C08J9/22—After-treatment of expandable particles; Forming foamed products
  • C08J9/228—Forming foamed products
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
  • C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
  • C08J9/22—After-treatment of expandable particles; Forming foamed products
  • C08J9/228—Forming foamed products
  • C08J9/232—Forming foamed products by sintering expandable particles
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
  • C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
  • C08J9/22—After-treatment of expandable particles; Forming foamed products
  • C08J9/228—Forming foamed products
  • C08J9/236—Forming foamed products using binding agents
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
  • B29B9/00—Making granules
  • B29B9/16—Auxiliary treatment of granules
  • B29B2009/166—Deforming granules to give a special form, e.g. spheroidizing, rounding
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
  • B29K2079/00—Use of polymers having nitrogen, with or without oxygen or carbon only, in the main chain, not provided for in groups B29K2061/00 - B29K2077/00, as moulding material
  • B29K2079/08—PI, i.e. polyimides or derivatives thereof
  • B29K2079/085—Thermoplastic polyimides, e.g. polyesterimides, PEI, i.e. polyetherimides, or polyamideimides; Derivatives thereof
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
  • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
  • B29K2105/04—Condition, form or state of moulded material or of the material to be shaped cellular or porous
• • 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
  • B32B2250/00—Layers arrangement
  • B32B2250/02—2 layers
• • 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
  • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
  • B32B2262/02—Synthetic macromolecular fibres
• • 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
  • B32B2266/00—Composition of foam
  • B32B2266/02—Organic
  • B32B2266/0214—Materials belonging to B32B27/00
• • B—PERFORMING OPERATIONS; TRANSPORTING
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• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
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  • B32B2266/00—Composition of foam
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• • B—PERFORMING OPERATIONS; TRANSPORTING
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  • B32B2266/00—Composition of foam
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• • B—PERFORMING OPERATIONS; TRANSPORTING
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  • B32B2307/00—Properties of the layers or laminate
  • B32B2307/30—Properties of the layers or laminate having particular thermal properties
  • B32B2307/306—Resistant to heat
  • B32B2307/3065—Flame resistant or retardant, fire resistant or retardant
• • B—PERFORMING OPERATIONS; TRANSPORTING
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  • B32B2307/00—Properties of the layers or laminate
  • B32B2307/40—Properties of the layers or laminate having particular optical properties
  • B32B2307/402—Coloured
  • B32B2307/4026—Coloured within the layer by addition of a colorant, e.g. pigments, dyes
• • B—PERFORMING OPERATIONS; TRANSPORTING
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  • B32B2307/00—Properties of the layers or laminate
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• • B—PERFORMING OPERATIONS; TRANSPORTING
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• • B—PERFORMING OPERATIONS; TRANSPORTING
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  • B32B2605/00—Vehicles
  • B32B2605/18—Aircraft
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
  • C08J2201/00—Foams characterised by the foaming process
  • C08J2201/02—Foams characterised by the foaming process characterised by mechanical pre- or post-treatments
  • C08J2201/03—Extrusion of the foamable blend
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
  • C08J2205/00—Foams characterised by their properties
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• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
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  • C08J2205/10—Rigid foams
• • C—CHEMISTRY; METALLURGY
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  • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
  • C08J2207/00—Foams characterised by their intended use
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
  • C08J2379/00—Characterised by the use of macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing nitrogen with or without oxygen, or carbon only, not provided for in groups C08J2361/00 - C08J2377/00
  • C08J2379/04—Polycondensates having nitrogen-containing heterocyclic rings in the main chain; Polyhydrazides; Polyamide acids or similar polyimide precursors
  • C08J2379/08—Polyimides; Polyester-imides; Polyamide-imides; Polyamide acids or similar polyimide precursors

Definitions

• polyetherimides (PEIs) fulfil the legal specifications demanded by the aviation industry for aircraft interiors. Specifically the demands on fire characteristics, stability to media and mechanical properties constitute a great challenge here.
• suitable polymer foams are produced as semifinished products. Reprocessing to give shaped articles is uneconomic in terms of time and material exploitation, for example by virtue of large amounts of cutting waste.
• the invention solves this problem in that the material which is suitable in principle can be processed to give particle foam mouldings. These mouldings can be produced without reprocessing in short cycle times and hence economically. Furthermore, this gives rise to new means of functional integration, for example by direct incorporation of inserts etc. in the foam, and with regard to freedom in terms of design.
• Foam materials suitable for installation in the aviation industry are common knowledge. However, the majority of the foams described for this purpose are composed of pure PMI (polymethacrylimide), PPSU (polyphenylene sulfones) or PES (polyether sulfones) only. Also to be found in the literature is PI (polyarylimide), although it is unsuitable from a toxicological point of view. All these materials have been used to date exclusively as block or slab materials.
• PESU poly(oxy-1,4-phenylsulfonyl-1,4-phenyl)
• DIAB Divinycell F product name
• particle foams based on polypropylene (EPP), polystyrene (EPS), thermoplastic polyurethane elastomer (E-TPU) or PMI (ROHACELL Triple F) have inadequate flame retardancy, while all inherently flame-retardant polymers that are suitable in principle, for example PES, PEI or PPSU, are processed solely to give slabstock foams according to the current prior art.
• EPP polypropylene
• EPS polystyrene
• E-TPU thermoplastic polyurethane elastomer
• PMI ROHACELL Triple F
• the problem addressed by the present invention was that of providing a composition for production of novel foams or composite materials, which may comprise, for example, a foam core with thermoplastic or crosslinked outer layers, for use in aircraft construction.
• novel foams or composite materials which may comprise, for example, a foam core with thermoplastic or crosslinked outer layers, for use in aircraft construction.
• the resulting foams are to have a good combination of usability at high temperatures, good mechanical properties, especially with regard to sufficient elongation at break, and at least sufficient flame retardancy for many applications in the field of vehicle and aircraft construction.
• the foam is to have high stability with respect to various liquid, acidic, basic or hydrophobic liquids, and with respect to emulsions.
• the foam is to be realizable from the composition to be developed by a wide variety of different methods and with a wide range of three-dimensional shapes, and only very little offcut material, if any at all, is to arise in the production of the final component.
• This inventive composition for production of foams is characterized in that it comprises a particle foam based on polyetherimides (PEI).
• PEI polyetherimides
• the particle foam according to the invention as a foamed material, has a glass transition temperature between 180 and 215° C., and the mean cell diameter of the particle foam therein is less than 2 mm, preferably less than 1 mm, more preferably less than 500 ⁇ m and most preferably less than 250 ⁇ m.
• the term “cell” describes a region in a foam that does not contain any matrix material but is at least partly surrounded thereby.
• Cells are also referred to here as pores.
• these pores or cells are closed, which in turn means that the cell is completely surrounded by the matrix material of the foam.
• open cells are present at least to some degree. These can nevertheless be identified as individual cells through the arrangement of incomplete walls or in the extreme case of bars. It is thus also possible to determine the size of such open cells.
• the size of a cell can in many cases be measured in a simple manner, for example with the aid of a microscope. Taking account of these factors as well, it is possible for the person skilled in the art to comply with the maximum cell size in the foam.
• a foam particle is understood in accordance with the invention to mean the region in a particle foam defined by foaming of an individual unfoamed or prefoamed particle.
• the boundary between the individual foam particles bonded to one another can easily be seen by the naked eye or determined under a light microscope. This is applicable especially when the boundaries between two foam particles are readily apparent. Since this need not necessarily be the case, however, the invention employs a simplified method: for this purpose, a theoretical average diameter of a foam particle is calculated in a simple manner from the diameter of the unfoamed particles, the total volume of the unfoamed particles and the volume of the finished foam part.
• the person skilled in the art is aware that, in the case of particle foams, a regular size distribution of the foam particles can be achieved in such a way that small deviations occur only in the edge regions of the foam part. It is a further advantage of the present invention that the proportion by volume of the gaps between the individual foam particles is so small that it is barely manifested in the measurement of volume of the finished foam part. Preferably, these foam particles in the finished foam are smaller than 1 cm, more preferably smaller than 0.7 cm.
• glass transition temperatures reported are measured by means of DSC (differential scanning calorimetry) unless otherwise stated.
• DSC differential scanning calorimetry
• the inventive composition for production of the particle foam in a first alternative embodiment of the invention, consists of 80% to 99.5% by weight of PEI.
• this composition includes 0.5% to 10% by weight, preferably 1% to 9% by weight, of a blowing agent. It may further contain inter alia 0% to 10% by weight, preferably 1% to 5% by weight, of additives.
• the additives may especially be flame retardants, plasticizers, pigments, UV stabilizers, nucleating agents, impact modifiers, adhesion promoters, rheology modifiers, chain extenders, fibres and/or nanoparticles.
• the flame retardants used are generally phosphorus compounds, in particular phosphates, phosphines or phosphites. Suitable UV stabilizers and/or UV absorbers are common general knowledge in the art. HALS compounds, Tinuvins or triazoles are generally used for this purpose.
• the impact modifiers used are generally polymer beads comprising an elastomeric and/or soft/flexible phase. These polymer beads frequently comprise core-(shell-)shell beads having an outer shell which, as such, is no more than lightly crosslinked and as purely polymer would exhibit at least minimal miscibility with the PEI. Any known pigments are employable in principle. Major amounts in particular do of course require testing as to their influence on the foaming operation, like all other additives employed in amounts above 0.1 wt %. This is not very burdensome to do for a person skilled in the art.
• Suitable plasticizers, rheology modifiers and chain extenders are common general knowledge in the art of producing sheetings, membranes or mouldings from PEI or blends comprising PEI, and are accordingly transferrable at minimal cost and inconvenience to the production of a foam from the composition according to the present invention.
• the optionally added fibres are generally known fibrous materials for addition to a polymer composition.
• the fibres are PEI fibres, PES fibres, PPSU fibres or blend fibres, the latter from a selection of the polymers mentioned.
• Nanoparticles for example in the form of tubes, platelets, rods, spheres or in other known forms, are inorganic materials in general. They may perform various functions in the final foam at one and the same time. This is because these particles act in part as nucleating agents in the foaming operation. The particles can further influence the mechanical properties as well as the (gas) diffusion properties of the foam. The particles further make an additional contribution to low flammability.
• phase-separating polymers may also be included as nucleating agents.
• nucleating agents in the context of nucleating agents in the composition, the polymers described must be viewed separately from the other nucleating agents, since the latter primarily exert influence on the mechanical properties of the foam, on the melt viscosity of the composition and hence on the foaming conditions.
• the additional effect of a phase-separating polymer as a nucleating agent is an additional desired effect of this component, but not the primary effect in this case. Therefore, these additional polymers appear further up in the overall tally, separate from the other additives.
• the additives may include up to 9% by weight of a further polymer component for adjustment of the physical properties.
• the additional polymers may, for example, be polyamides, polyolefins, in particular PP, polyesters, in particular PET, sulfur-based polymers, for example PSU, PPSU, PES or poly(meth)acrylimide.
• blowing agent is relatively free and for a person skilled in the art is dictated in particular by the foaming method chosen, its solubility in the polymer and the foaming temperature.
• Suitable examples are alcohols, e.g. isopropanol or butanol, ketones, such as acetone or methyl ethyl ketone, alkanes, such as isobutane, n-butane, isopentane, n-pentane, hexane, heptane or octane, alkenes, e.g. pentene, hexene, heptene or octene, CO 2 , N 2 , water, ethers, e.g. diethyl ether, aldehydes, e.g. formaldehyde or propanal, hydro(chloro)fluorocarbons, chemical blowing agents or mixtures of two or more thereof.
• alcohols e.g. is
• Chemical blowing agents are relatively or completely non-volatile substances which undergo chemical decomposition under foaming conditions to form the actual blowing agent upon decomposition.
• tert-Butanol is a very simple example thereof in that it forms isobutene and water under foaming conditions.
• Further examples are NaHCO 3 , citric acid, citric acid derivatives, azodicarbonamide (ADC) and/or compounds based thereon, toluenesulfonylhydrazine (TSH), oxybis(benzosulfohydroazide) (OBSH) or 5-phenyltetrazole (5-PT).
• the particle foam according to the invention has a tensile strength to ISO1926 of greater than 0.5 MPa, an elongation at break to ISO01926 of between 8% and 12%, a shear modulus to ASTM C273 at room temperature of greater than 8 MPa, a shear resistance to ASTM C273 at room temperature of greater than 0.45 MPa, a compressive modulus to ISO 844 at room temperature of greater than 13 MPa, and a compressive strength to ISO 844 at room temperature of greater than 0.4 MPa.
• the particle foam according to the invention is usable with satisfaction of the fire protection specifications or fire properties according to FAR 25.852 that are of particular importance for use in the interior of an aircraft in the aviation industry.
• isotropic mechanical properties for a particle foam in many cases, whereas a corresponding slabstock foam often has anisotropic mechanical properties in that they differ in one area and in an axis at right angles to this area. According to specific use, isotropic mechanical properties may quite possibly be advantageous, especially when there are uniform compressive stresses from different directions.
• the foams according to the invention have a degree of foaming that amounts to a reduction in the density with respect to the unfoamed material of between 1% and 98%, preferably between 50% and 97%, more preferably between 70% to 95%.
• the foam preferably has a density between 20 and 1000 kg/m 3 , preferably 40 and 250 kg/m 3 , especially preferably between 50 and 150 kg/m 3 .
• a composition consisting of 80% to 99.5% by weight of PEI, 0.5% to 10% by weight of blowing agent and 0% to 10% by weight of additives is processed by means of an extruder having a perforated plate to give foamed or foamable pellets.
• the temperatures between intake zone and screw tip are preferably within a range between 320 and 400° C.
• there is usually no homogeneous temperature over this distance but instead, for example, a gradient with rising temperature in conveying direction of the polymer melt.
• the temperature of the perforated plate is between 250 and 350° C., and the melt temperature on exit through the perforated plate is between 230 and 360° C.
• the loading with the blowing agent is generally effected in the extruder.
• the pellets then foam as they exit from the perforated plate when the pressure in the underwater pelletization is lower than the expansion force of the blowing agent.
• the pellets thus foamed are then preferably processed further to give a particle foam.
• the composition on exit from the extruder can be guided into an underwater pelletizer.
• This underwater pelletizer is designed to have a combination of temperature and pressure such that foaming is prevented.
• This procedure provides a pellet material laden with blowing agent, which may later be expanded to the desired density by a renewed supply of energy and/or further processed into a bead foam workpiece by optional moulding.
• the energy input necessary for pre-foaming can be effected by means of contact heating, for example in an air circulation oven, or in a radiation-based manner by means of IR or microwave radiation.
• a composition consisting of 90% to 100% by weight of PEI and 0% to 10% by weight of additives is processed by means of an extruder with a perforated plate likewise at first to give pellets, but is not laden with a blowing agent.
• the temperatures—which are again not necessarily uniform—between intake zone and screw tip are within a range between 320 and 400° C.
• the temperature of the perforated plate is likewise between 250 and 350° C., and the melt temperature on exit through the perforated plate is between 230 and 360° C.
• the pellets are subsequently laden with a blowing agent in an autoclave in such a way that they contain between 0.5% and 10% by weight of blowing agent.
• the blowing agent-laden pellets can then be foamed by expansion and/or by heating to a temperature exceeding 200° C. to obtain a particle foam.
• the composition can be foamed at a temperature between 150 and 250° C. and at a pressure between 0.1 and 2 bar.
• the actual foaming if it does not follow after the extrusion, is effected at a temperature between 180 and 230° C. in a standard pressure atmosphere.
• a composition still without blowing agent is admixed with the blowing agent in an autoclave at a temperature, for example, between 20 and 120° C. and at a pressure, for example, between 30 and 100 bar and subsequently expanded inside the autoclave by reducing the pressure and raising the temperature to the foaming temperature.
• the composition admixed with the blowing agent is cooled down in the autoclave and deautoclaved after cooling. This composition is then expandable at a later date by heating to the foaming temperature. This may also take place, for example, under further moulding or in combination with other elements such as inserts or facing layers.
• the particle foam produced is subsequently adhesive-bonded, sewn or welded to a cover material.
• “Welded” means here that heating of the components gives rise to cohesion or adhesion between the materials, for example through partial filling of open pores at the foam surface with cover material.
• the cover material may comprise wood, metals, decorative films, composite materials, prepregs or other known materials.
• the particle foam produced can alternatively also be foamed in the presence of a cover material such that it is bonded thereto by means of adhesive bonding or welding.
• the PEI can alternatively also be applied on exit from the extruder into an optionally heated mould, optionally containing cover materials.
• foaming is effected with shaping to give a particle foam or a composite material.
• the composition, on exit from the extruder, can be guided into a foam spraying apparatus. In this apparatus, expansion then takes place directly with moulding.
• the particle foams or composite materials can be provided with inserts during the foaming and/or channels can be incorporated into the particle foam.
• Foams according to the invention find use in the construction of spacecraft or aircraft, especially in the interior or exterior thereof. This may include the particle foams, whether produced by the process according to the invention or not, and likewise the composite materials realized therefrom. More particularly, by virtue of their low flammability, the foams of the present invention can also be installed in the interior of these vehicles.
• the pure PEI particle foams are especially suitable for incorporation within the interior of an aircraft.
• Aircraft especially include, as well as jets or small aircraft, helicopters or even spacecraft. Examples of installation in the interior of such an aircraft are, for example, the tablets that can be folded down on the reverse side of a seat in a passenger aircraft, the filling of a seat, or an internal partition, and also, for example, in internal doors.
• Particle foams based on a blend containing PEI are additionally also suitable for incorporation in the exterior of an aircraft as well.
• the “exterior” means not just as a filling in the outer skin of an aircraft, but especially also in an aircraft nose, in the tail region, in the wings, in the outside doors, in the control surfaces or in rotor blades.

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