WO1999050059A1 - Elements sandwichs constitues de couches exterieures en plastique et d'une ame - Google Patents

Elements sandwichs constitues de couches exterieures en plastique et d'une ame Download PDF

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Publication number
WO1999050059A1
WO1999050059A1 PCT/EP1999/002370 EP9902370W WO9950059A1 WO 1999050059 A1 WO1999050059 A1 WO 1999050059A1 EP 9902370 W EP9902370 W EP 9902370W WO 9950059 A1 WO9950059 A1 WO 9950059A1
Authority
WO
WIPO (PCT)
Prior art keywords
sandwich
mold
smc
low
sandwich elements
Prior art date
Application number
PCT/EP1999/002370
Other languages
German (de)
English (en)
Inventor
Wilfried GRÜDL
Manfred Gruber
Hermann Jacob
Helmut MÖSLEIN
Roland Schwall
Original Assignee
Menzolit-Fibron Gmbh
KÖGEL Fahrzeugwerke 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 Menzolit-Fibron Gmbh, KÖGEL Fahrzeugwerke AG filed Critical Menzolit-Fibron Gmbh
Publication of WO1999050059A1 publication Critical patent/WO1999050059A1/fr

Links

Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
    • E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
    • E04C2/296—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and non-metallic or unspecified sheet-material
    • 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
    • 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
    • B29C70/28—Shaping operations therefor
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • B29C70/46—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
    • 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B63—SHIPS OR OTHER WATERBORNE VESSELS; RELATED EQUIPMENT
    • B63B—SHIPS OR OTHER WATERBORNE VESSELS; EQUIPMENT FOR SHIPPING 
    • B63B3/00—Hulls characterised by their structure or component parts
    • B63B3/14—Hull parts
    • B63B3/68—Panellings; Linings, e.g. for insulating purposes

Definitions

  • Sandwich elements made of plastic cover layers and a core
  • the invention relates to sandwich elements made of plastic cover layers and a core, processes for their production and their use.
  • the state of the art for trucks is box bodies made of sheet steel, of a steel-wood composite construction, and for temperature-controlled containers, in particular bodies made of sandwich elements.
  • Such sandwich elements have a cover layer and a core on the outside and inside.
  • the cover layers can consist of metal or plastic materials (DE-A 39 16 065).
  • the sandwich elements used for insulated containers should preferably have a high degree of rigidity with a low weight. They must be able to cope with the load caused by forklifts, in the side wall area from the load caused by storey loading and in the roof area from the load caused by the suspension of loads. In order to be able to be used for the transport of frozen products, for example, they must ensure that the low transport temperature is maintained at high outside temperatures.
  • plastic sandwich elements with a length of up to approximately 16,000 mm in various widths and thicknesses are known.
  • the core of each of these elements is partially or completely enclosed by plastic cover layers.
  • These sandwich elements are self-supporting and achieve a high payload for the entire vehicle due to their low weight. Depending on the dimensions of the container, they are manufactured in customized shapes.
  • the various glass fiber mats (depending on the type of stress different fiber structure) as well as the insulating foam are tailored to the vehicle. Then an unsaturated polyester resin with hardener is applied. Because of the small amount of hardener to be added there are always problems with the correct dosage. The resin is poured into the mobile tundish and distributed in the prepared form. Because the distribution is controlled manually, the amount of resin distributed varies greatly from element to element.
  • a surface fleece is placed on top of the surface fleece, several glass fiber and covering fabric mats, usually as a combination mat. After each layer, resin must be applied manually with the tundish. A complex extraction system must ensure that the MAK values are adhered to. Then the foam sheets, including wood or metal reinforcements, are cut to fit the vehicle.
  • Fabric mats are placed between the individual foam sheets to reinforce the wall. Each of these mats must also be soaked in resin by hand.
  • the inserted foam sheets are covered with resin from the tundish. Glass fiber and fabric mats are put on again as a top layer (combination mat). Resin is poured over the completely filled form and a cover fleece is applied. After a final pouring of resin, the mold is closed with the gel-coated lid.
  • the closed mold is inserted into a hot plate press and the resin is cured under pressure (approx. 1 bar) and temperature (approx. 60 ° C).
  • the object of the present invention was therefore to provide sandwich elements which can be produced by a simple method and which do not have the disadvantages of the sandwich elements known from the prior art.
  • the special feature of the sandwich elements according to the invention is that low-pressure SMC is used instead of the cover layers previously produced in situ in such cases and the reinforcements made of glass fiber reinforced plastic (GRP).
  • GRP glass fiber reinforced plastic
  • SMC stands for "Sheet Molding Compound” and is the English name for a resin mat according to DIN 16913. SMC is generally used to refer to a flowable resin mat with isotropic properties and random fiber distribution in the mat plane. SMC is a flat semi-finished product based on unsaturated polyester resin and / Glass fibers are usually used as reinforcement fibers, but other materials are also suitable for reinforcement. A typical SMC recipe consists of approx. 30% polymer, approx. 30% filler and approx. 30% fibers, the rest settles from aggregates, such as color pigments, hardeners, dispersing agents and similar substances. SMC is manufactured from a resin master paste and reinforcement - 4 -
  • the resin base paste is applied to two carrier foils. These carrier foils are drawn through the SMC machine and thereby transport the resin paste onto which the reinforcing fibers are sprinkled or placed. After the reinforcing fibers have been applied, both foils are pressed together so that a kind of sandwich is created. This sandwich is pulled through an impregnation line, which uses pressure and flexing movements to ensure that the fibers are evenly wetted with the resin base paste. At the end of the machine, the semi-finished product is wound on rolls. A ripening process that can be initiated in a chemical and / or physical manner is of crucial importance. After this maturation process, the SMC can be processed further.
  • the SMC is usually processed into molded parts in heated steel tools.
  • the mold temperature is generally about 135 to 155 ° C.
  • the decomposition of the hardener is started by the mold temperature and the molding compound undergoes an exothermic crosslinking reaction.
  • the material When processing in press tools, the material is usually dosed manually. Maintaining precise dosing quantities is generally very important for problem-free production.
  • the SMC is usually prepared and weighed according to a cutting plan. Weighing out the blank serves as a control and enables a possible correction of the blank. Then the SMC is placed on the tool and the tool is closed. The pressure is built up and held until the molded part is completely hardened.
  • the SMC according to the invention contains as a base paste a mixture of at least one unsaturated polyester resin and / or vinyl ester resin as the base component, at least one shrinkage-compensating additive, at least one hardener and additives.
  • the base paste preferably contains at least one resin based on maleic acid, isophthalic acid, orthophthalic acid, terephthalic acid, tetrahydrophthalic acid, adipic acid or bisphenol-A, as vinyl ester resin preferably at least one resin based on bisphenol-A or novolac or mixtures of these resins .
  • Saturated polyesters or products based on polyurethane, polyvinyl acetate, polymethyl methacrylate, polystyrene or styrene-butadiene or mixtures of these additives, for example, are added to this base component as a shrinkage-compensating additive.
  • Suitable components are known per se to the person skilled in the art and are commercially available for semi-finished SMC products.
  • Organic peroxides that start at the lowest possible temperatures are used as hardeners. Examples include t-butyl per-2-ethylhexanoate, bis- (4-t-butylcyclohexyl) peroxydicarbonate, benzoyl peroxide and methyl isobutyl ketone peroxide. Mixtures of these peroxides, which are known per se in SMC technology, can also be used. - 6 -
  • this resin base paste also contains the usual additives known to those skilled in the art, such as additives to ensure storage stability, additives for deaeration, thixotropic agents, thickening aids, fillers and pigments, and, depending on the application, adhesives and / or release agents.
  • additives include, for example, the known components which stabilize peroxide-containing UP resin batches, the known foam-inhibiting polymers, silicas such as, for example, aerosils, calcium carbonate, aluminum trihydrate, kaolin and barium sulfate.
  • the stock paste according to the invention contains 10 to 34% by weight, preferably 17 to 34% by weight of unsaturated polyester resin and / or vinyl ester resin, 1 to 15% by weight, preferably 1.5 to 13.5% by weight, of shrinkage-compensating additive, and at least one hardener in amounts which exclude undercuring, preferably 0.1 to 2% by weight hardener.
  • Up to 0.2 wt.%, Preferably 0.03 to 0.15 wt.% Inhibitor, up to 0.2 wt.%, Preferably 0.03 to 0.15 wt.% Deaerator can be used as additives , up to 2% by weight, preferably 0.15 to 1% by weight thixotropic agent, up to 0.2% by weight, preferably 0.015 to 0.1% by weight thickening aid, 1 to 30% by weight , preferably 4 to 24% by weight of fillers and up to 4% by weight, preferably 0.15 to 2% by weight of pigment substances, and depending on the application 1 to 15% by weight, preferably 1.5 to 13, 5 wt .-% adhesive and / or 1 to 2 wt .-%, preferably 1, 2 to 1, 8 wt .-% release agent are added.
  • the resin paste is mixed with a thickener.
  • Alkali and / or alkaline earth oxides or hydroxides and / or isocyanates can be used as thickeners.
  • Magnesium oxide, magnesium hydroxide and / or calcium hydroxide may be mentioned by way of example.
  • 0.1 to 2% by weight, preferably 0.15 to 1.7% by weight, of thickening agent can be added to the stock paste.
  • the resin paste according to the invention is applied to two carrier foils. These are then pulled through the SMC machine as usual - 7 -
  • reinforcing fibers Depending on the required strength, 10 to 70% by weight, preferably 20 to 60% by weight, of reinforcing fibers are embedded.
  • the reinforcing fibers can be used as a mat, fabric, fleece, continuous fibers or as clippings or as combinations of these shapes. Possible reinforcing fibers are: glass fibers, carbon fibers, kevlar, aramid, polymer fibers or fibers made from renewable raw materials such as flax, hemp, banana or coconut. Combinations of these materials can also be used.
  • the rest of the process is the same as for standard SMC. After the ripening process (chemical and / or physical thickening), the low-pressure SMC according to the invention thus produced can be processed further.
  • This low-pressure SMC is used to produce the sandwich elements according to the invention.
  • the shape required for the elements is cleaned as usual and adjusted to the required dimensions.
  • the mold and the mold cover are provided with a release agent in order to be able to remove the finished element from the mold without problems.
  • a gel coat fine-layer resin with a self-separating effect is preferably used. It consists, for example, of unsaturated, thixotropic polyester resin based on dicarboxylic acid neopentyl glycol in a highly reactive setting and is characterized by high water resistance and mechanical resistance. Alternatively, the gel coat can also be integrated in the low-pressure SMC according to the invention.
  • a single-layer or multilayer film or lacquer film can also be inserted into the mold or into the mold cover.
  • the insertion of the film can expediently be facilitated by suction using a vacuum.
  • a multilayer film it expediently consists of a carrier film with an applied layer of colored lacquer and clear lacquer. Even more - 8th -
  • the sandwich element can be individually designed using such a single-layer or multilayer or lacquer film. In this way, painting, so to speak, can be integrated into the manufacturing process of the sandwich elements according to the invention.
  • a surface fleece for example made of glass fibers or polyester fibers and impregnated with UP resin
  • the first layer of the low-pressure SMC webs is inserted.
  • the foam sheets tailored to the vehicle, including any necessary reinforcements made of wood, metal or reinforcements made of low-pressure SMC sheets, are inserted into the mold.
  • further low-pressure SMC webs and the cover fleece are put on and the mold is coated with the release agent, gel coat, single or multi-layer or. Lacquered lid closed.
  • the foam sheets which serve as spacers and insulation, should have a low density, high pressure resistance, low thermal conductivity and should also be environmentally friendly.
  • Polyurethane plates or plates made of thermoplastic material are advantageously used as foam plates.
  • a multi-layer low-pressure SMC structure of the sandwich elements is of course also possible, for example by providing not only cover layers and reinforcements made of low-pressure SMC, but also intermediate layers or other structures made of low-pressure SMC.
  • the closed mold is inserted into the hot plate press and at a temperature which depends on the hardener used and is sufficient for the hardener to start, preferably at about 60 ° C., a pressure which is sufficient for the internal connection of the foam plates to the low pressure SMC is sufficient, preferably pressed at a pressure of 1 to 2 bar.
  • Figure 1 shows the schematic structure of a sandwich element according to the invention.
  • the numbers mean: (1) gel coat; (2) surface fleece, (3) hardened low pressure SMC, (4) foam sheet.
  • the sandwich elements according to the invention can be used in a variety of ways.
  • worktops residential units, for example residential containers, cold stores, box bodies, cooling units, refrigerated bodies, cold rooms, sanitary rooms, for example wet cells, isolation cells or clean rooms, can be produced from the sandwich elements according to the invention.
  • Other areas of application are wagon, bus and shipbuilding. They are preferably used in commercial vehicle construction and in the manufacture of containers.

Abstract

L'invention concerne des éléments sandwichs constitués de couches extérieures en plastique (3) et d'une âme (4), leur procédé de production et leur utilisation. Les couches extérieures en plastique (3) des éléments sandwichs selon l'invention sont fabriquées dans un mélange à mouler en feuille (SMC) basse pression et elles entourent partiellement ou complètement l'âme (4).
PCT/EP1999/002370 1998-03-30 1999-03-30 Elements sandwichs constitues de couches exterieures en plastique et d'une ame WO1999050059A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE19814043.6 1998-03-30
DE19814043 1998-03-30

Publications (1)

Publication Number Publication Date
WO1999050059A1 true WO1999050059A1 (fr) 1999-10-07

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Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/EP1999/002370 WO1999050059A1 (fr) 1998-03-30 1999-03-30 Elements sandwichs constitues de couches exterieures en plastique et d'une ame

Country Status (2)

Country Link
DE (1) DE19914327A1 (fr)
WO (1) WO1999050059A1 (fr)

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2301984A1 (fr) * 2009-09-23 2011-03-30 Blas Escudero Sanchez Réplique de bouteille de polyester renforcé aux fibres de verre
US8021595B2 (en) 2004-07-20 2011-09-20 B.I. Group, Plc Composite material
FR2957958A1 (fr) * 2010-03-29 2011-09-30 Olivier Leroy Mur plastique mobile pour piscine
CN102821933A (zh) * 2010-03-25 2012-12-12 戴姆勒股份公司 用于加工smc多层结构件的方法
CN103407166A (zh) * 2013-05-28 2013-11-27 常熟市金亿复合材料有限公司 一种聚苯乙烯泡沫板的制作方法

Families Citing this family (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE10123176C2 (de) * 2001-05-12 2003-08-07 Daimler Chrysler Ag Verfahren zur Herstellung von Sandwichbauteilen mit einer Deckschicht und einer Schaum aufweisenden Kernschicht
DE10351181A1 (de) * 2003-11-03 2005-06-02 Dr.Ing.H.C. F. Porsche Ag Wand für einen Aufbau eines Kraftfahrzeugs
DE102015119401A1 (de) 2015-11-11 2017-05-11 Airbus Operations Gmbh Verfahren zur Herstellung eines Sandwichbauteils
DE102016220806A1 (de) * 2016-10-24 2018-04-26 Bayerische Motoren Werke Aktiengesellschaft Verfahren zur Herstellung eines Außenhautbauteils eines Fahrzeugs

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2481412A2 (fr) * 1980-04-29 1981-10-30 Quillery Piece de structure autoportantes et autoresistantes en matiere synthetique en particulier pare-chocs de vehicule, et procede pour leur fabrication
JPH0679742A (ja) * 1992-09-03 1994-03-22 Asahi Fiber Glass Co Ltd 水タンク用パネルの製造法

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2481412A2 (fr) * 1980-04-29 1981-10-30 Quillery Piece de structure autoportantes et autoresistantes en matiere synthetique en particulier pare-chocs de vehicule, et procede pour leur fabrication
JPH0679742A (ja) * 1992-09-03 1994-03-22 Asahi Fiber Glass Co Ltd 水タンク用パネルの製造法

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
DATABASE WPI Section Ch Week 9416, Derwent World Patents Index; Class A32, AN 94-131671, XP002109519 *

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US8021595B2 (en) 2004-07-20 2011-09-20 B.I. Group, Plc Composite material
EP2301984A1 (fr) * 2009-09-23 2011-03-30 Blas Escudero Sanchez Réplique de bouteille de polyester renforcé aux fibres de verre
CN102821933A (zh) * 2010-03-25 2012-12-12 戴姆勒股份公司 用于加工smc多层结构件的方法
CN102821933B (zh) * 2010-03-25 2014-09-17 戴姆勒股份公司 用于加工smc多层结构件的方法
US8932499B2 (en) 2010-03-25 2015-01-13 Daimler Ag Method for producing an SMC multi-layer component
FR2957958A1 (fr) * 2010-03-29 2011-09-30 Olivier Leroy Mur plastique mobile pour piscine
CN103407166A (zh) * 2013-05-28 2013-11-27 常熟市金亿复合材料有限公司 一种聚苯乙烯泡沫板的制作方法

Also Published As

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