WO2011026977A1 - Pièce moulée composite destinée en particulier à la fabrication de meubles - Google Patents

Pièce moulée composite destinée en particulier à la fabrication de meubles Download PDF

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Publication number
WO2011026977A1
WO2011026977A1 PCT/EP2010/063044 EP2010063044W WO2011026977A1 WO 2011026977 A1 WO2011026977 A1 WO 2011026977A1 EP 2010063044 W EP2010063044 W EP 2010063044W WO 2011026977 A1 WO2011026977 A1 WO 2011026977A1
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WO
WIPO (PCT)
Prior art keywords
weight
component
relation
styrene
amsan
Prior art date
Application number
PCT/EP2010/063044
Other languages
German (de)
English (en)
Inventor
Klaus Hahn
Holger Ruckdaeschel
Ingo Bellin
Peter Merkel
Markus Hartenstein
Manfred Pawlowski
Original Assignee
Basf Se
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 Basf Se filed Critical Basf Se
Priority to EP10751926A priority Critical patent/EP2475522A1/fr
Publication of WO2011026977A1 publication Critical patent/WO2011026977A1/fr

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    • B32B21/02—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board the layer being formed of fibres, chips, or particles, e.g. MDF, HDF, OSB, chipboard, particle board, hardboard
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    • C08J9/14—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 by a physical blowing agent organic
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Definitions

  • the invention relates to a composite molding, in particular for furniture construction, comprising a core layer of an extruded foam and at least one further layer, a process for its preparation, and the use of the composite molding in furniture, the construction industry, in the automotive industry and in boat and shipbuilding.
  • Composite moldings for use in the furniture industry have long been known. They have, in addition to a core layer, further layers, for example cover layers, films or veneers, and optionally a stabilizing frame construction. If such composite moldings are to be used as lightweight components, it is desirable to have a core layer with the lowest possible density, which may, however, affect the further performance characteristics as little as possible.
  • German utility model DE 296 09 442 U1 describes a molded part, in particular for furniture or furniture parts, which contains a core layer of a paper honeycomb material, cover layers of, for example, chipboard or MDF (middle density fiber) sheets as cover layers and a frame construction.
  • the disadvantage here is that the frame construction is imperative for stability reasons and that fittings are difficult to install, since the core layer is not solid.
  • LU-A 80594 describes a sandwich element with an aluminum honeycomb panel. In addition to economic disadvantages due to the use of expensive aluminum fittings are difficult to install here.
  • German utility model DE 202005012486 U1 door blanks are described from a lightweight board with polyurethane (PU) core.
  • PU polyurethane
  • EPS expanded polystyrene
  • Sandwich panels are usually offered by the manufacturers without edge coating, since these are applied individually in a further processing stage. For those companies where such edge coating is used, it is important that this can be done with common tools, adhesives and coating techniques that are also applicable to wood materials. Here also remains a wide room for improvement in the known materials.
  • Another object was to provide a composite molding, in particular for furniture construction, which has a high compressive and flexural strength at low density and, if desired, a high heat resistance.
  • the invention therefore relates to a composite molding, in particular for the furniture industry, comprising a first layer and one or more further layers connected to the first layer, the first layer being a closed-cell extrusion foam board having a cell count of 1 to 30 cells per mm and a density of 20-150 g / l, obtainable by (a) heating a polymer component P formed from
  • P1 100 to 0 wt .-% (based on P ') of one or more alpha-methylstyrene-acrylonitrile copolymers (AMSAN) containing
  • AMSAN alpha-methylstyrene-acrylonitrile copolymers
  • P1 1) from 18 to 40% by weight (based on AMSAN) of copolymerized acrylonitrile
  • P12 from 60 to 82% by weight (based on AMSAN) of copolymerized ⁇ -methylstyrene (P121) or of a copolymerized mixture of ⁇ -methylstyrene and styrene ( P122)
  • P13 0 to 22 wt .-% (based on AMSAN) of at least one copolymerized monomer selected from the group consisting of alkyl (meth) acrylates, (meth) acrylic acid, maleic anhydride and maleimides.
  • SAN styrene-acrylonitrile copolymers
  • P21) from 18 to 40% by weight (based on SAN) of copolymerized acrylonitrile
  • P22 from 60 to 82% by weight (based on SAN) of copolymerized styrene
  • P23) from 0 to 22% by weight (based on SAN) at least a copolymerized monomer selected from the group consisting of alkyl (meth) acrylates, (meth) acrylic acid, maleic anhydride and maleimide, the sum of the percentages by weight of P1 and P2 being 100% by weight, based on P ',
  • thermoplastic polymers selected from the group consisting of styrene polymers and copolymers, polyolefins, polyacrylates, polycarbonates (PC), polyesters, polyamides, polyether sulfones (PES). Polyether ketones (PEK) and polyether sulfides (PES), to form a polymer melt,
  • the invention likewise relates to a process for producing a composite molding according to the invention, comprising the steps of a) providing a polymer component (P) which is formed from
  • a component P ' consisting of P1
  • P1 100 to 0 wt .-% (based on P') of one or more alpha-methylstyrene-acrylonitrile copolymers (AMSAN) containing
  • AMSAN alpha-methylstyrene-acrylonitrile copolymers
  • P1 1) from 18 to 40% by weight (based on AMSAN) of copolymerized acrylonitrile
  • P12 from 60 to 82% by weight (based on AMSAN) of copolymerized ⁇ -methylstyrene (P121) or of a copolymerized mixture of alpha-
  • P13 0 to 22 wt .-% (based on AMSAN) of at least one copolymerized monomer selected from the group consisting of alkyl (meth) acrylates, (meth) acrylic acid, maleic anhydride and maleimides.
  • P2 0 to 100 wt .-% (based on P ') of one or more styrene-acrylonitrile copolymers (SAN) containing, preferably consisting of, P21) 18 to 40 wt .-% (based on SAN) copolymerized acrylonitrile .
  • SAN styrene-acrylonitrile copolymers
  • P23 0 to 22% by weight (based on SAN) of at least one copolymerized monomer selected from the group consisting of alkyl (meth) acrylates, (meth) acrylic acid, maleic anhydride and maleimide, wherein the sum of the weight percentages of (P1) and P1 is 100% by weight, based on
  • thermoplastic polymers selected from the group consisting of styrene polymers and copolymers, polyolefins; Polyacrylates, polycarbonates (PC), polyesters, polyamides, polyether sulfones (PES), polyether ketones (PEK) and polyether sulfides (PES), (b) heating the polymer component (P) to form a polymer melt,
  • the invention further relates to the use of the composite molding according to the invention in furniture construction, in the construction industry, in exhibition construction, automotive engineering and in boat and shipbuilding.
  • the composite molding according to the invention is characterized by a combination of lower density, high compressive and flexural strength and increased heat resistance.
  • the foam structure is more homogeneous and the mechanical properties can be adapted to the load direction required by the application by adjusting the cell orientation during foam extrusion. Due to their good heat resistance compared to materials such as XPS, the composite moldings according to the invention can be processed more easily, have a high compressive and flexural strength and require at densities between 50 and 100 g / l no frame construction.
  • composite moldings containing alpha-methylstyrene / acrylonitrile (AMSAN) show a high heat resistance.
  • Sandwich panels containing the foam material according to the invention allow a coating of the edges according to customary methods in wood construction with conventional tools and coating techniques.
  • the extrusion foam board used according to the invention for the core layer generally has a density of from 20 to 150 g / l, preferably from 50 to 130 g / l, particularly preferably from 60 to 120 g / l.
  • the extrusion foam according to the invention has a cell count in the range 1 to 30 cells per mm, preferably from 3 to 20 cells per mm, in particular from 3 to 25 cells per mm.
  • closed-cell extruded foam means that the cells, measured in accordance with DIN ISO 4590, are closed to at least 90%, in particular to 95-100%.
  • Component P1 consists of one or more alpha-methylstyrene-acrylonitrile copolymers (AMSAN) containing, preferably consisting of,
  • P12 from 60 to 82% by weight, preferably from 60 to 75% by weight, particularly preferably from 65 to 75% by weight (based on AMSAN) of copolymerized ⁇ -methylstyrene (P121) or of a copolymerized mixture of alpha-
  • P13) 0 to 30% by weight, preferably less than 20% by weight, particularly preferably less than 5% by weight (based on AMSAN), of at least one copolymerized monomer from the group consisting of alkyl (meth) acrylates, (meth) acrylic acid, maleic anhydride and maleimides.
  • alkyl (meth) acrylates are understood as meaning both alkyl acrylates and alkyl methacrylates.
  • (meth) acrylic acid is meant both acrylic acid and methacrylic acid.
  • Preferred alkyl (meth) acrylates are formed from (meth) acrylic acid and CrC 6 - alcohols such as methanol, ethanol, 1-propanol, 2-propanol, n-butanol, sec-butanol, isobutanol, tert-butanol, 1 Pentanol and its isomers, 1-hexanol and its isomers and cyclohexanol.
  • maleimides are maleimide itself, N-alkyl-substituted maleimides (preferably with C 1 -C 6 -alkyl) and N-phenyl-substituted maleimides.
  • component P1 contains no further (0 wt .-%) comonomers P13.
  • the component P1 contains 0.1 to 22 wt .-%, preferably 1 to 20 wt .-% of one or more comonomers (P13), preferably from the group consisting of alkyl (meth) acrylates, (meth) acrylic acid, maleic anhydride and maleimides.
  • P13 comonomers
  • the component (P12) is alpha-methylstyrene (P121). In a further preferred embodiment, the component (P12) consists of a mixture of styrene and alpha-methylstyrene (P122).
  • component P1 contains no comonomer (P13) and component (P12) consists of alpha-methylstyrene (P121).
  • P1 consists of one or more, preferably one, copolymer with component (P121).
  • P1 consists of one or more, preferably one, copolymers with component (P122). In another embodiment, P1 consists of one or more, preferably one, copolymer with component (P121) and one or more, preferably one, copolymer with component (P122).
  • AMSAN (P1) with the component (P121) AMSAN types are available from (P1 1) 18 to 35 wt .-%, preferably 27 to 33 wt .-% (based on (P1)) of acrylonitrile and
  • AMSAN (P1) with the component (P122) are polymers obtainable from (P1221) from 61 to 81% by weight (based on (P1)) of alpha-methylstyrene,
  • (P1 1) 18 to 34 wt .-% (based on (P1)) acrylonitrile.
  • the SAN component (P2) generally contains from 18 to 40% by weight, preferably from 25 to 35% by weight and in particular from 30 to 35% by weight of copolymerized acrylonitrile and generally from 60 to 82% by weight, preferably from 65 to 75 wt .-% and particularly preferably 65 to 75 wt .-% of copolymerized styrene (in each case based on SAN).
  • the SAN consists of the components (P21) and (P22) and optionally (P23).
  • the SAN (P2) may optionally contain 0 to 22% by weight of at least one copolymerized monomer from the group consisting of alkyl (meth) acrylates, (meth) acrylic acid, maleic anhydride and maleimides (component P23). In a preferred embodiment, the SAN (P2) contains no monomer of the component (P23).
  • the SAN used in the invention (P2) generally have a melt volume rate MVR (220 ° C / 10 kg) according to ISO 1 13 in the range of 5 to 20 cm 3/10 min.
  • Suitable types of SAN are, for example, polymers of BASF SE such as Luran 3380, Luran 33100 and Luran 2580.
  • component ( ⁇ ') contains no (0 wt .-%) AMSAN (P1).
  • the component (P) contains no (0 wt .-%) styrene-acrylonitrile copolymer (P2).
  • the component ( ⁇ ') contains one or more, preferably one, copolymer (P1), preferably in an amount of at least 5 wt .-%, and one or more, preferably a copolymer (P2), preferably in an amount of at least 5% by weight.
  • component (P) contains no (0 wt.%) Thermoplastic polymer (P3).
  • the polymer component P (and thus also the extrusion foam) contains 0.1 to 15 wt .-%, particularly preferably 0.5 to 5 wt .-% of a thermoplastic polymer (P3) (in each case based on P).
  • P3 thermoplastic polymer
  • Styrene polymers and copolymers polyolefins, polyacrylates, polycarbonates (PC), polyesters, polyamides, polyethersulfones (PES), polyether ketones (PEK), polyethersulfides (PES) or mixtures thereof are optionally used as thermoplastic polymers (P3) of the polymer component P.
  • Suitable styrene copolymers are, for example, acrylonitrile-butadiene-styrene (ABS), styrene-maleic anhydride (SMA), acrylonitrile-styrene-acrylic ester (ASA) and styrene-methacrylic acid.
  • ABS acrylonitrile-butadiene-styrene
  • SMA styrene-maleic anhydride
  • ASA acrylonitrile-styrene-acrylic ester
  • P3 styrene-methacrylic acid
  • polystyrene As component (P3) and polystyrene can be used. However, this is not preferred. Suitable polyolefins (as component (P3)) are, for example, polypropylene (PP) polyethylene (PE) and polybutadiene.
  • a suitable polyacrylate is, for example, polymethyl methacrylate (PMMA).
  • Suitable polyesters are, for example, polyethylene terephthalate (PET) and polybutylene terephthalate (PBT).
  • Suitable polyamides are, for example, polyamide 6 (PA6), polyamide 6,6, polyamide 6, 1 and polyamide 6 / 6,6.
  • the polymer component P contains no (0% by weight) styrene copolymer (as component (P3)). In a further preferred embodiment, the polymer component P contains no (0 wt .-%) thermoplastic polymer (P3).
  • the components (P3) preferably contain no polystyrene.
  • component (P) consists of component (P1), this component (P1) preferably containing component (P121) and preferably no component (P13), more preferably component (P121) and none Component (P13).
  • the component (P) consists of the component (P1) and the component (P2), wherein preferably the component (P1) contains the component (P121) and / or no component (P13), and / or the component (P2) contains no component (P23) and wherein particularly preferably the component (P1) contains the component (P121) and no component (P13) and the component (P2) contains no component (P23).
  • the two components (P1) and (P2) each consist of one (1) copolymer. It is furthermore particularly preferred in this embodiment if component (P) consists of from 20 to 98% by weight, and preferably from 50 to 97% by weight (P1), and the amount (P2) complementary to 100% by weight ,
  • component P consists of component (P1) and component (P3), component (P1) preferably containing component (P121) and / or no component (P13) and / or component (P3 ) Is styrene-maleic anhydride (SMA) and / or acrylonitrile-styrene acrylic ester (ASA), and wherein component (P1) more preferably contains component (P121) and no component (P13) and component (P3) contains styrene-maleic anhydride (SMA) and / or acrylonitrile-styrene-acrylic ester (ASA).
  • the components (P1) and (P3) each consist of one (1) copolymer or polymer.
  • the component P consists of the components (P1), (P2) and (P3), wherein the component (P1) preferably contains the component (P121) and / or no component (P13) and / or wherein the Component (P2) preferably contains no component (P23) and / or component (P3) is preferably styrene-maleic anhydride (SMA) and / or acrylonitrile-styrene-acrylic ester (ASA), and where component (P1) is particularly preferably component (P121) and no component (P13), component (P2) contains no component (P23) and component (P3) is styrene-maleic anhydride (SMA) and / or acrylonitrile-styrene-acrylic ester (ASA).
  • the components (P1), (P2) and (P3) are each made of a copolymer or polymer.
  • Particularly preferred in this embodiment is (P) from the component (P2), i. the component (P3) does not exist.
  • composition of the polymer component P can be selected according to the desired properties of the foam molding.
  • the copolymers used according to the invention in particular when using AMSAN, the heat resistance is improved.
  • the blowing agent component (T) comprises (and preferably consists of)
  • Preferred alcohols are methanol, ethanol, 1-propanol, 2-propanol, 1-butanol, 2-butanol, 2-methylpropanol and tert-butanol. Particularly preferred are 2-propanol and ethanol. Particularly preferred is ethanol.
  • Ci-C 4- carbonyl compounds are ketones, aldehydes, carboxamides and Carbonklareester 1 - 4 carbon atoms.
  • Suitable ketones are acetone and methyl ethyl ketone, preferred formates being methyl formate, ethyl formate, n-propyl formate and i-propyl formate. Preference is given to methyl formate and acetone. Especially preferred is acetone. Also preferred is a mixture of ethanol and acetone, in particular with an acetone content of at least 50 wt .-% (based on acetone and ethanol).
  • the co-propellant (b2) and the carbon dioxide (b1) may contain water (b3). Water enters the blowing agent component T, especially by the use of technical alcohols and / or ketones. The water concentration is in the above ranges.
  • the blowing agent component is substantially anhydrous.
  • Particularly preferred are mixtures of carbon dioxide and ethanol, carbon dioxide and acetone, carbon dioxide and methyl formate, carbon dioxide and mixtures of ethanol and acetone in the above mixing ratios.
  • the blowing agent component (T) is added to the polymer melt in a proportion of 1 to 12 wt .-%, preferably 1 to 8 and particularly preferably 1, 5 to 7% by weight (in each case based on P).
  • the blowing agent component (T) is added to the polymer melt in a proportion of 1 to 4.5% by weight (based on P).
  • a suitable composition of the blowing agent component (T) contains from 15 to 95% by weight of component (b1) and from 5 to 85% by weight of component (b2).
  • the proportion of component (b1) based on P at most 6 wt .-% and the proportion of component (b2) based on P at most 5 wt .-%, and the total content of components (b1) and (b2) based on P maximum 8 wt .-%.
  • the proportion of component (b1) based on P is at most 4.5 wt .-% and the proportion of component (b2) based on P at most 4 wt .-%.
  • the blowing agent component (T) is added to the polymer melt in a proportion of from 1 to 4.5% by weight, based on P, and the blowing agent component contains from 15 to 40% by weight (based on (T) carbon dioxide - oxide (component b1)).
  • the blowing agent component (T) is added to the polymer melt in an amount of from 1 to 4.5% by weight, based on P, and the blowing agent component contains from 15 to 40% by weight (based on (T) Carbon dioxide (component (b1) and the extrusion foam has a density in the range from 50 to 130 g / l, preferably from 60 to 120 g / l.
  • the blowing agent component (T) may be incorporated into a molten polymer component P by any method known to those skilled in the art.
  • extruders or mixers for example kneaders
  • the blowing agent is mixed with the molten polymer component P under elevated pressure.
  • the pressure must be high enough to substantially prevent foaming of the molten polymer material and to achieve homogeneous distribution of the blowing agent component (T) in the molten polymer component P.
  • Suitable pressures are 50 to 500 bar (absolute), preferably 100 to 300 bar (absolute), more preferably 150 to 250 bar (absolute).
  • step (b) of the process according to the invention must be selected so that the polymeric material is in the molten state. For this it is necessary that the polymer component P is heated to a temperature above the melting or glass transition temperature. Suitable temperatures are generally at least 150 ° C, preferably 160 to 290 ° C, more preferably 180 to 250 ° C. Step (b) may be carried out continuously or batchwise, preferably step (b) is carried out continuously.
  • the blowing agent can be added in the melt extruder (primary extruder) or in a downstream step.
  • the extrusion foam board used according to the invention preferably contains an additive component (AK). Suitable additives are known to the person skilled in the art.
  • nucleating agent is added to the polymer component P.
  • Nucleating agents which may be used are finely divided, inorganic solids such as talc, metal oxides, silicates or polyethylene waxes in amounts of generally from 0.1 to 10% by weight, preferably from 0.1 to 3% by weight, particularly preferably from 0.1 to 1.5 % By weight, based on P, are used.
  • the average particle diameter of the nucleating agent is generally in the range from 0.01 to 100 ⁇ m, preferably from 1 to 60 ⁇ m.
  • a particularly preferred nucleating agent is talc, for example talc from Luzenac Pharma.
  • the nucleating agent may be added by methods known to those skilled in the art.
  • additives such as nucleating agents, fillers (for example mineral fillers such as glass fibers), plasticizers, flame retardants, IR absorbers such as carbon black or graphite, aluminum powder and titanium dioxide, soluble and insoluble dyes and pigments may be added.
  • Preferred additives are graphite and carbon black.
  • graphite is added in amounts of generally 0.05 to 25 wt .-%, particularly preferably in amounts of 2 to 8 wt .-%, based on (P).
  • Suitable particle sizes for the graphite used are in the range from 1 to 50 ⁇ m, preferably in the range from 2 to 10 ⁇ m.
  • Suitable flame retardants are, for example, tetrabromobisphenol A, brominated polystyrene oligomers, tetrabromobisphenol A diallyl ether, expandable graphite, red phosphorus, triphenyl phosphate and 9,10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide.
  • Another suitable flame retardant is, for example, hexabromocyclododecane (HBCD), in particular the industrial products which essentially contain the o, ß and ⁇ isomer and an addition of synergists such as dicumyl.
  • HBCD hexabromocyclododecane
  • Particularly preferred are brominated aromatics, such as tetrabromobisphenol A, and brominated styrene oligomers.
  • the total amount of additives is generally 0 to 30 wt .-%, preferably 0 to 20 wt .-%, based on the total weight of the extrusion foam.
  • the dyes and pigments are added in amounts ranging from 0.01 to 30, preferably in the range of 1 to 5 wt .-% (based on P).
  • a dispersing assistant for example organosilanes, polymers containing epoxy groups or maleic anhydride-grafted styrene polymers.
  • Preferred plasticizers are fatty acid esters, fatty acid amides and phthalates, which can be used in amounts of from 0.05 to 10% by weight, based on the polymer component P.
  • the preparation of the extrusion foam board used according to the invention can be carried out according to steps (a) to (e) of the process described above.
  • step (b) of the process of the invention the polymer component P is heated to obtain a polymer melt.
  • the formation of a polymer melt is understood to mean a plasticization of the polymer component in a broader sense, ie the conversion of the solid constituents into a deformable or flowable state.
  • the polymer component is heated to a temperature above the melting or glass transition temperature. Suitable temperatures are generally at least 150 ° C, preferably 160 to 280 ° C, more preferably 180 to 240 ° C.
  • the heating of the polymer component can be accomplished by any means known in the art, such as by means of an extruder, a mixer (for example, a kneader).
  • the use of melt extruders (primary extruders) is preferred.
  • Step (b) may be carried out continuously or batchwise, with a continuous mode being preferred.
  • Step (c) of the process according to the invention comprises introducing the blowing agent component (T) into the polymer melt produced in step (b) to form a foamable melt.
  • the blowing agent component (T) is added to the polymer melt in a proportion of 1 to 12% by weight, preferably 1 to 4.5% by weight (in each case based on P).
  • the blowing agent component (T) can be incorporated into the polymer melt (P) by any method known to those skilled in the art.
  • extruders or mixers for example, kneaders
  • the blowing agent is mixed with the molten polymer component under elevated pressure. The pressure must be so high that substantially prevents foaming of the molten polymer material and a homogeneous distribution of the blowing agent component is achieved in the molten polymer component.
  • Suitable pressures are 50 to 500 bar (absolute), preferably 100 to 300 bar (absolute), more preferably 150 to 250 bar (absolute).
  • the temperature in step (c) of the process according to the invention must be selected so that the polymeric material is present in the molten state. Therefore, step (c) is generally carried out at temperatures of at least 150 ° C, preferably 160 to 280 ° C, particularly preferably 180 to 240 ° C. Step (c) may be carried out continuously or batchwise, preferably, step (c) is carried out continuously.
  • the blowing agent can be added in the melt extruder (primary extruder) or in a downstream step.
  • the preparation of the foamable polymer melt is carried out in XPS extruders known to the person skilled in the art, for example via a tandem structure consisting of a melting extruder (primary extruder) and a cooling extruder (secondary extruder).
  • the process can be carried out continuously and discontinuously, wherein the polymer component (P) is melted in the primary extruder (step (b)) and the addition of the blowing agent (step (c)) to form a foamable melt also takes place in the primary extruder.
  • the foamable melt provided with blowing agent in the secondary extruder to a suitable temperature for foaming of 50-180 ° C, preferably to a temperature of 80-150 ° C, cooled.
  • Step (d) of the process of the invention comprises foaming the foamable polymer melt to obtain an extrusion foam.
  • the melt is to promote by a suitable device, such as a nozzle plate.
  • a suitable device such as a nozzle plate.
  • the nozzle plate is heated at least to the temperature of the blowing agent-containing polymer melt.
  • the temperature of the nozzle plate is 60 to 200 ° C.
  • the temperature of the nozzle plate is 1 10 to 180 ° C.
  • Step (d) is also conducted at a temperature at which the polymeric material to be foamed is in a molten state. In general at temperatures of 50 to 170 ° C, preferably at 90 to 150 ° C, more preferably at 1 10 to 140 ° C.
  • step (c) Characterized in that the blowing agent-containing polymer melt is transferred in step (c) in a region in which a lower pressure prevails, the blowing agent is converted into the gaseous state. Due to the large volume increase, the polymer melt is expanded and foamed.
  • one or more additives are added to the polymer component P in at least one of the steps a), b), c) and d) (step e)).
  • the geometric shape of the cross section of the extruded foams obtainable by the process according to the invention is essentially determined by the choice of the nozzle plate and, if appropriate, by suitable downstream devices such as plate calibrations, roller conveyor prints or tape strips, is freely selectable and can be adapted to the requirements for the composite molded article.
  • the extruded foams obtainable by the process according to the invention preferably have a rectangular cross-section.
  • the thickness of the extrusion foams is determined by the height of the nozzle plate slot.
  • the width of the extrusion foams is determined by the width of the nozzle plate slot.
  • the length of the extruded foam parts is determined in a subsequent working step by known methods familiar to the person skilled in the art, such as gluing, welding, sawing and cutting.
  • Particularly preferred are extruded foam parts with a plate-shaped geometry. Plate-shaped means that the dimension of the thickness (height) is small in comparison with the dimension of the width and the dimension of the length of the molding.
  • step f) at least one further layer is applied to the extrusion foam board obtained in step d) by known methods known to the person skilled in the art.
  • the composite molded parts according to the invention contain at least one further layer.
  • the first layer is preferably connected to at least two surfaces with one or more further layers. Further preferably, the first layer is on at least two surfaces (in the case of a rectangular cross-section top and bottom), also preferably all surfaces are connected to one or more further layers.
  • the structure of the composite molding consists of one or more core layers, one or more cover layers and a surface layer.
  • the structure of the composite molding consists of a core layer and a surface layer.
  • aminoplast resin films in particular melamine films, PVC (polyvinyl chloride), glass fiber reinforced plastic (GRP), for example a composite of polyester resin, epoxy resin, or polyamide and glass fibers, prepregs, films, laminates, for example HPL ( high pressure laminates) and CPL (continuous pressure laminates), veneers, and metal, especially aluminum or lead coatings suitable.
  • fabrics and nonwovens in particular of natural and / or synthetic fibers.
  • the moldings (s) all materials into consideration, which are made of wood strips, wood fibers, wood chips, wood, wood veneers, glued woods, veneers or a combination of the corresponding manufacturing processes, such as veneer or plywood panels, wood chips produced wood-based materials, for example particleboard or OSB (Oriented Strand Boards) and wood fiber materials such as LDF, MDF and HDF boards.
  • wood materials are made from the corresponding wood particles made with the addition of natural and / or synthetic binders by hot pressing.
  • OSB chipboard
  • HDF high-density fiberboard
  • MDF medium-density fiberboard
  • chipboard or MDF / HDF which are optionally surface-coated on one side, i. by painting, veneering, an applied film (melamine film) or laminate.
  • planking takes place according to known, familiar to the expert methods.
  • the surface layer is pressed, for example, by methods known to those skilled in the art with the molded parts (s) according to the invention.
  • the sizing liquor can be applied to the core layer according to the invention, the board can be laid on and pressed under temperature and pressure.
  • the pressing pressure is typically below 100 bar, the pressing time is usually up to 15 minutes and the pressing temperature is usually at a maximum of 100 ° C.
  • Adhesives may include conventional materials, for example dispersion adhesives, for example white glue, epoxy resins, formaldehyde condensation resins, such as phenolic resins, urea-formaldehyde resins, melamine-formaldehyde resins, melamine-urea-formaldehyde resins, resorcinol and phenolic resorcinol resins, isocyanate adhesives, polyurethane adhesives and Hot melt adhesive can be used.
  • dispersion adhesives for example white glue, epoxy resins, formaldehyde condensation resins, such as phenolic resins, urea-formaldehyde resins, melamine-formaldehyde resins, melamine-urea-formaldehyde resins, resorcinol and phenolic resorcinol resins, isocyanate adhesives, polyurethane adhesives and Hot melt adhesive can be used.
  • one or more layers of the composite molding are made of materials capable of emitting formaldehyde, it is advantageous to subject the corresponding layer or composite molding to a polyamine treatment as described in WO 2007/082837.
  • the composite molding according to the invention can be finished after the application of the surface layer, for example by cutting to the plate format and calibrating.
  • the composite molded part is designed as a sandwich panel, in particular for furniture construction.
  • a plate in which at least one side length is a multiple of the height, contains one or more core layers, at least one of which consists of the extrusion foam according to the invention, optionally one or more intermediate or functional layers and one or more cover layers which cover the upper and lower surfaces of the plate.
  • one or more edges of the sandwich panel can also be coated.
  • the edges are not coated, since this coating is individualized for the desired later application and takes place at a later point in time than the production of the sandwich plate.
  • the cover layer (s) are preferably selected from the materials listed above.
  • the sandwich panel may contain, in addition to the core layer (s), functional layers which facilitate further processing, for example the attachment / insertion of fastening elements.
  • the extrusion layer according to the invention is light, homogeneous, hydrophobic, heat-resistant, pressure-insensitive in all directions and has a coefficient of expansion which is the same in the longitudinal and in the transverse direction. It can be firmly connected with standard glues and adhesives.
  • the composite moldings according to the invention show a combination of:
  • the foam density allows proper start-up and operation of the aggregates of edge banding machines (flush milling , Profiling, grinding, caps) - networked structure (tear-free format saw cut with standard machines and tools)
  • edge can be coated with hot-melt adhesive in the standard temperature range of 180-210 ° C, for example 190 ° C),
  • a particular advantage is that the new materials make it much easier to machine the edges, which is of great advantage since the fact that the edges are coated often does not have the plate manufacturers' special techniques and equipment.
  • the composite molding according to the invention preferably has a density in the range from 50 to 300 g / l, particularly preferably 50 to 150 g / l, in particular 50 to 100 g / l.
  • the composite molding according to the invention preferably contains no frame construction.
  • the composite molding according to the invention is preferably used for the production of furniture, door, room, wall, ceiling, separating or floor elements, for example in building, drywall or interior work, for example as a laminate, insulation, plate or packaging material. Preference is also given to an application in exhibition construction, automotive engineering, for example for motorhomes, boat building, yacht building and shipbuilding
  • Luran HH120 AMSAN with an acrylonitrile content of 29.5% by weight and a viscosity number of 57 ml / g commercial product of BASF SE
  • Luran 3360 SAN with an acrylonitrile content of 33% by weight and a viscosity number of 60 ml / g Common product of BASF SE
  • Luran 2580 SAN with an acrylonitrile content of 25% by weight and a viscosity number of 80 ml / g commercial product of BASF SE
  • the polymers used were continuously fed together with talc to a melt-down extruder.
  • the total throughput of the polymers was 60 kg / h.
  • the propellants (C0 2 , ethanol, acetone) were fed continuously through an injection opening introduced into the melting extruder.
  • the blowing agent-containing melt was cooled in a subsequent cooling extruder and extruded through a slot die.
  • the intumescent melt was calibrated with a plate calibrator and continuously withdrawn through a roller belt.
  • Table 1 shows inventive extrusion foams (B1-B17) in which SAN types of different molecular weights were used.
  • Tables 1 and 3 show extruded foams B9-B17 according to the invention, in which AMSAN and SAN / AMSAN mixtures with different blowing agent components were used.
  • Table 2 shows extruded foams B9-B17 according to the invention, in which AMSAN and SAN / AMSAN mixtures with different blowing agent components were used.
  • Example 18 Production of a composite molding made of foam board, formica and veneer layer
  • Extruded foam boards according to Example B2 and B6 were coated with a Resopalplatte and a wood veneer.
  • a Kauritleim was used as adhesive, the pressing conditions were 90 to 95 C and 100 atü.
  • Example 19 Production of a composite molding made of foam board and beech veneer on both sides
  • Example 20 A 20 x 20 cm 2 large and 0.5 cm thick foam sheet according to Example 5 with a density of 70 g / l was pasted on both sides with a 1, 5 mm thick beech veneer (glue application 200 g / m 2 white glue, screw press, pressing time 120 min . at room temperature). The resulting composite moldings meet the requirements z. B. be placed on chipboard.
  • Example 20 Production of a composite molding made of foam board and one-sided book veneer
  • a 20 x 20 cm 2 large and 0.5 cm thick foam sheet according to Example 18 with a density of 70 g / l was stuck on one side with a 1, 5 mm thick beech veneer (glue application 170 g / m 2 white glue, screw press, pressing time 120 min . at room temperature).
  • a 20 x 20 cm 2 large and 0.5 cm thick foam sheet according to Example 18 with a density of 70 g / l was covered on both sides with 3.5 mm thick MDF boards (Homanit GmbH & Co KG, Herzberg am Harz, Germany) (Glue application 200 g / m 2 white glue, screw press, pressing time 120 min at room temperature).

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Organic Chemistry (AREA)
  • Health & Medical Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Textile Engineering (AREA)
  • Wood Science & Technology (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Materials Engineering (AREA)
  • Manufacture Of Porous Articles, And Recovery And Treatment Of Waste Products (AREA)
  • Compositions Of Macromolecular Compounds (AREA)

Abstract

L'invention concerne une partie moulée composite, destinée en particulier à la fabrication de meubles, contenant une couche centrale et une ou plusieurs couches, la couche centrale étant conçue sous la forme d'un panneau de mousse d'extrusion à cellules fermées comprenant un nombre de cellules de 1 à 30 cellules par mm et une densité de 20 à 200 g/l, lequel peut être obtenu par moussage d'extrusion d'une masse fondue pouvant être moussée, comprenant (a) le réchauffement d'un composant polymère P, qui est formé à partir de 85 à 100 % en poids d'un composant P', comprenant P1) 100 à 0 % en poids (par rapport à P') d'un ou de plusieurs copolymères alpha-méthylstyrène-acrylonitrile (AMSAN), contenant P11) 18 à 40 % en poids (par rapport à AMSAN) d'acrylonitrile polymérisé, P12) 60 à 82 % en poids (par rapport à AMSAN) d'alpha-méthylstyrène polymérisé (P121) ou un mélange polymérisé d'alpha-méthylstyrène et de styrène (P122), P13) 0 à 22 % en poids (par rapport à AMSAN) d'au moins un monomère polymérisé choisi dans le groupe consituté par les (méth)acrylates d'alkyle, l'acide (méth)acrylique, l'anhydride d'acide maléique et les maléinimides, et P2) 0 à 100 % en poids (par rapport à P') d'un ou de plusieurs copolymères styrène-acrylonitrile (SAN), contenant, de préférence se composant de, P21) 18 à 40 % en poids (par rapport à SAN) d'acrylonitrile polymérisé, P22) 60 à 82 % en poids (par rapport à SAN) de styrène polymérisé et P23) 0 à 22 % en poids (par rapport à SAN) d'au moins un monomère polymérisé choisi dans le groupe constitué par les (méth)acrylates d'alkyle, l'acide (méth)acrylique, l'anhydride d'acide maléique et le maléinimide, le total des pourcentages en poids de (P1) et P2 étant de 100 % en poids par rapport à P', et P3) 0 à 15 % en poids (par rapport à P) d'un ou de plusieurs polymères thermoplastiques choisis dans le groupe comprenant les polymères et copolymères de styrène ; les polyoléfines ; les polyacrylates ; les polycarbonates (PC) ; les polyesters ; les polyamides ; les polyéthersulfures (PES) ; les polyéthercétones (PEK) et les polyéthersulfures (PES), pour la formation d'une masse fondue polymère, (b) l'introduction dans la masse fondue polymère de 1 à 12 % en poids (par rapport à P) d'un composant agent propulseur T, qui contient de préférence moins de 0,2 % en poids d'eau (par rapport à P), contenant b1) 15 à 95 % en poids (par rapport à T) de dioxyde de carbone et b2) 5 à 85 % en poids (par rapport à T) d'un ou de plusieurs co-agents propulseurs choisis dans le groupe constitué par les alcools en C1-C4 et les composés carbonyle en C1-C4, pour la formation d'une masse fondue pouvant être moussée, (c) l'extrusion de la masse fondue pouvant être moussée dans une zone de pression plus faible avec moussage pour obtenir la mousse d'extrusion, (d) éventuellement l'addition d'additifs au composant polymère P dans au moins l'une des étapes a), b) et/ou c).
PCT/EP2010/063044 2009-09-07 2010-09-06 Pièce moulée composite destinée en particulier à la fabrication de meubles WO2011026977A1 (fr)

Priority Applications (1)

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EP10751926A EP2475522A1 (fr) 2009-09-07 2010-09-06 Pièce moulée composite destinée en particulier à la fabrication de meubles

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EP09169566 2009-09-07
EP09169566.8 2009-09-07

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WO2011026977A1 true WO2011026977A1 (fr) 2011-03-10

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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2562324A1 (fr) * 2011-08-25 2013-02-27 Tavapan SA Plaque en matière composite pour la fabrication d'élargissement de cadres su fenêtres et portes et d'utilisation comme panneau de construction léger avec un coeur en matière plastique cellulaire et deux couches extérieures et un procédé pour la fabrication
US8636929B2 (en) 2010-05-21 2014-01-28 Basf Se Nanoporous foamed active compound-containing preparations based on pharmaceutically acceptable thermoplastically workable polymers
CN105437622A (zh) * 2015-12-11 2016-03-30 南京工程学院 一种工字型夹芯复合板材的制备工艺

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LU80594A1 (fr) 1977-12-05 1979-06-15 Accumulateurs Fixes Methode de precharge de l'electrode negative d'accumulateurs nickel-cadmium alcalins
DE29609442U1 (de) 1996-05-28 1996-09-26 Steinhoff Laminat Gmbh Formteil
NL1005985C2 (nl) * 1997-05-06 1998-11-09 Dsm Nv Polymeerschuim uit met water verschuimde polymeersamenstellingen.
DE202005012486U1 (de) 2005-08-09 2005-10-27 Swl Tischlerplatten Betriebs Gmbh Türrohling
EP1661939A1 (fr) 2004-11-29 2006-05-31 Basf Aktiengesellschaft Plaques de mousse de polystyrène à faible conductivité thermique
WO2007082837A1 (fr) 2006-01-17 2007-07-26 Basf Se Procédé pour réduire l'émission de formaldéhyde de matériaux dérivés du bois
US20070256379A1 (en) 2006-05-08 2007-11-08 Edwards Christopher M Composite panels
US20080299379A1 (en) * 2007-06-04 2008-12-04 Dow Global Technologies Inc. Composite material and method of making the composite material
US20090062410A1 (en) * 2007-08-27 2009-03-05 Dow Global Technologies Inc. Method of forming extruded polystyrene foams and the products made therefrom

Patent Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
LU80594A1 (fr) 1977-12-05 1979-06-15 Accumulateurs Fixes Methode de precharge de l'electrode negative d'accumulateurs nickel-cadmium alcalins
DE29609442U1 (de) 1996-05-28 1996-09-26 Steinhoff Laminat Gmbh Formteil
NL1005985C2 (nl) * 1997-05-06 1998-11-09 Dsm Nv Polymeerschuim uit met water verschuimde polymeersamenstellingen.
EP1661939A1 (fr) 2004-11-29 2006-05-31 Basf Aktiengesellschaft Plaques de mousse de polystyrène à faible conductivité thermique
DE202005012486U1 (de) 2005-08-09 2005-10-27 Swl Tischlerplatten Betriebs Gmbh Türrohling
WO2007082837A1 (fr) 2006-01-17 2007-07-26 Basf Se Procédé pour réduire l'émission de formaldéhyde de matériaux dérivés du bois
US20070256379A1 (en) 2006-05-08 2007-11-08 Edwards Christopher M Composite panels
US20080299379A1 (en) * 2007-06-04 2008-12-04 Dow Global Technologies Inc. Composite material and method of making the composite material
US20090062410A1 (en) * 2007-08-27 2009-03-05 Dow Global Technologies Inc. Method of forming extruded polystyrene foams and the products made therefrom

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US8636929B2 (en) 2010-05-21 2014-01-28 Basf Se Nanoporous foamed active compound-containing preparations based on pharmaceutically acceptable thermoplastically workable polymers
EP2562324A1 (fr) * 2011-08-25 2013-02-27 Tavapan SA Plaque en matière composite pour la fabrication d'élargissement de cadres su fenêtres et portes et d'utilisation comme panneau de construction léger avec un coeur en matière plastique cellulaire et deux couches extérieures et un procédé pour la fabrication
CN105437622A (zh) * 2015-12-11 2016-03-30 南京工程学院 一种工字型夹芯复合板材的制备工艺

Also Published As

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