WO2014125126A1 - Profilé métallique isolé et sa production - Google Patents

Profilé métallique isolé et sa production Download PDF

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Publication number
WO2014125126A1
WO2014125126A1 PCT/EP2014/053156 EP2014053156W WO2014125126A1 WO 2014125126 A1 WO2014125126 A1 WO 2014125126A1 EP 2014053156 W EP2014053156 W EP 2014053156W WO 2014125126 A1 WO2014125126 A1 WO 2014125126A1
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WO
WIPO (PCT)
Prior art keywords
profile
man
fibres
weight
foam composite
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Application number
PCT/EP2014/053156
Other languages
English (en)
Inventor
Michaeel Emborg
Dorte Bartnik JOHANSSON
Original Assignee
Rockwool International A/S
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Publication date
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Publication of WO2014125126A1 publication Critical patent/WO2014125126A1/fr

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Classifications

    • 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
    • B29C44/12—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
    • B29C44/18—Filling preformed cavities
    • 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
    • C08J9/0085—Use of fibrous compounding ingredients
    • 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
    • B29K2075/00—Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material
    • 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
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/12—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of short lengths, e.g. chopped filaments, staple fibres or bristles
    • B29K2105/122—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of short lengths, e.g. chopped filaments, staple fibres or bristles microfibres or nanofibers
    • 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
    • C08J2375/00—Characterised by the use of polyureas or polyurethanes; Derivatives of such polymers
    • C08J2375/04—Polyurethanes

Definitions

  • the invention relates to insulated metal profiles for use in the building industry, especially in circumstances where high compressive strength, high bending resistance and high fire resistance are required. More particularly, the invention relates to metal profiles insulated with a defined foam composite material. Background of the invention
  • Elongate hollow metal profiles are widely used in the building industry for various purposes. Such profiles generally define at least one elongate cavity or channel along the length of the profile which can be open or enclosed. Such profiles can be used, for instance, in the construction and support of a variety of building structures, including light steel frame constructions, e.g. for greenhouses, playhouses, winter gardens, extensions, but also for building components like windows, doors, portals and for other purposes such as attaching facade cladding to buildings.
  • a hollow metal profile may be load bearing and it is important that it exhibits high resistance to compression and/or high resistance to bending. It is also important that it shows good fire resistance and is able to withstand the temperatures that are experienced in normal use, which can extend over a wide range even in a non-fire situation. However, it is also important that the hollow profile retains its benefit of low mass.
  • metals are generally good thermal conductors there is a tendency for metal profiles to act as thermal bridges. It is known to provide hollow metal profiles whose channel(s) contain insulating material. Examples of such systems include those disclosed in US 6,406,078. In this case the foamed material is included in order to increase strength and stiffness of the hollow element. This discloses that the metal profile may include insulating material which can be foamed. This publication also mentions that the insulating material may contain filler such as glass or plastic microspheres, silica flume, calcium carbonate, milled glass fibre and chopped glass strand. There is no detail given of the size of any such filler particles.
  • DE 2722824 also discloses a hollow metal profile into which a foamable composition is introduced and foamed so as to fill the enclosed channel defined by the profile. It would be desirable to provide a metal profile which has good insulation values and which also exhibits improved structural properties, including resistance to compression. It would be desirable to provide such a profile which exhibits improved resistance to bending. It would also be desirable to provide such a profile which exhibits improved fire resistance and improved behaviour under temperature extremes in normal use.
  • an insulated metal profile comprising an elongate metal profile which defines at least one longitudinal channel, wherein said at least one channel contains a core formed of a polymeric foam composite material comprising a polymeric foam and discontinuous man-made vitreous fibres, wherein at least 50% by weight of the man-made vitreous fibres present in the foam composite material have a length of less than 100 micrometers.
  • the insulated metal profiles of the invention can be used in numerous applications in the building industry where a profile is required to be load bearing and/or to exhibit fire resistance and/or to exhibit extreme temperature resistance.
  • a polymeric foam composite comprising the defined man-made vitreous fibres has the advantage of high compressive strength, and high resistance to elevated temperature, especially in comparison with use of foam materials which do not contain such man-made vitreous fibres.
  • the bending strength of the profiles can be improved.
  • the polymeric foam composite material used according to the invention shows improved dimensional stability on ageing and in a fire situation, thus aiding in retention of the dimensional stability of the insulated profile as a whole.
  • the insulated metal profile defines at least one elongate cavity, or channel.
  • the channel is a longitudinal channel, that is it extends along the length of the elongate profile.
  • Such hollow profiles are well-known in the construction industry.
  • the invention is of particular value in the case where the channel is an open channel, that is the channel is open on at least one side. Because metallic materials are generally good thermal conductors, a hollow profile which fully encloses a channel will have greater potential to create thermal bridges in structures in which it is used.
  • the use of a hollow profile in which the channel is open, and filled with the defined polymeric foam composite enables reduction of such thermal bridging.
  • this advantage is negated to some extent by the fact that the fire properties of the insulated profile are inferior.
  • conventional polymeric foam materials, and metal profiles containing them are often placed in fire Euro class (EN 13501 ) E or F.
  • the polymeric foam composite used in the invention has much improved fire resistance and small scale flame tests show that it potentially can meet the requirements of Euro fire class B, even when the hollow profile has an open channel so that the polymeric foam composite material is exposed.
  • the profile may have any appropriate cross-sectional configuration, for instance U-shape, C-shape, V-shape or J-shape.
  • the invention is also applicable to profiles of l-shape cross-section or W-shape cross-section.
  • the cross-sectional configuration of the channel can be square or rectilinear or curved, for instance semi-circular.
  • the profile can take the form of a tube or beam having any appropriate cross-section, for instance circular, oval, square, rectangular or triangular.
  • the channel contains a core formed of the defined polymeric foam composite.
  • the polymeric foam composite fills substantially the entire channel provided in the metal profile. Generally it is in contact with substantially the entire inner surface of the channel.
  • a single insulated metal profile may define more than one channel. At least one channel must be provided with a core formed of the defined polymeric foam composite. However, if the profile includes more than one channel then more than one channel may be provided with the defined core formed of polymeric foam composite, and indeed all channels may be so provided.
  • the metal profile is elongate. Generally it has a ratio of length:width of at least 4:1 , preferably at least 8:1 , in particular at least 10:1.
  • the metal profile may have any of the standard lengths known in the art, for instance at least 300 mm, 750 mm, 1000 mm, 1500 mm up to 5000 mm.
  • the width may be in the range 20 - 250 mm, preferably 50 to 150 mm and the height may be in the range 10 mm to 100 mm, preferably 20 to 50 mm.
  • the elongate profile is formed of metal and for instance may be copper or steel (e.g. stainless steel).
  • the metal profile is formed of aluminium. Aluminium profiles are advantageously used in the building industry for their low weight and chemical resistance.
  • the thickness of the metal forming the profile in particular the portion of the profile which defines the channel, can for instance be in the range 0.4 to 5mm, preferably 0.5 to 2mm.
  • the invention has the particular benefit that the bending strength of the profile as a whole can be improved by the inclusion of the polymeric foam composite material, even at the same metal thickness.
  • a metal profile can be provided having equivalent bending strength even at lower metal thickness, and hence at lower material cost.
  • the insulated profiles according to the invention can be used as load-bearing profiles and in the production of structures, especially those which are required to have low mass. They can be used, for instance, in the construction and support of a variety of building structures, including light steel frame constructions, e.g. for greenhouses, playhouses, winter gardens, extensions, but also for building components like windows, doors, portals and for other purposes such as attaching facade cladding to buildings. They can be used for the support of windows, roller shutters, shutters, the construction of greenhouses and playhouses.
  • Structural uses require that a profile be able to withstand a variety of temperatures, for instance -30°C to 50°C.
  • the invention is particularly useful in circumstances such as the construction of roof elements and greenhouses, where the profile may be subjected to high temperatures in normal use, for instance up to 90°C.
  • the invention makes use of the polymeric foam composite material described in our earlier application filed on 18 August 201 1 and having the application number EP 1 1177971.6 and in our international application PCT/EP2012/066196 filed on 20 August 2012. The disclosure of those applications is incorporated herein by reference.
  • the polymeric foam composite material used in the present invention can be produced from a foamable composition comprising a foam pre-cursor and discontinuous man-made vitreous fibres, wherein at least 50% by weight of the man-made vitreous fibres have a length of less than 100 micrometres.
  • discontinuous man-made vitreous fibres is well understood by those skilled in the art. Discontinuous man-made vitreous fibres are, for example, those produced by internal or external centrifugation, for example with a cascade spinner or a spinning cup. The weight percentage of fibres in the polymeric foam composite material or in the foamable composition above or below a given fibre length is measured with a sieving method. A representative sample of the man-made vitreous fibres is placed on a wire mesh screen of a suitable mesh size (the mesh size being the length and width of a square mesh) in a vibrating apparatus. The mesh size can be tested with a scanning electron microscope according to DIN ISO3310.
  • the upper end of the apparatus is sealed with a lid and vibration is carried out until essentially no further fibres fall through the mesh (approximately 30 mins). If the percentage of fibres above and below a number of different lengths needs to be established, it is possible to place several screens with incrementally increasing mesh sizes on top of one another. The fibres remaining on each screen are then weighed. In order to measure the length of fibres in a pre-formed polymeric foam composite, it is possible to burn off the foam from a representative sample of the foam composite by placing it in a 590°C furnace for 20 min. This method is according to ASTM C612-93. The remaining fibres can then be analysed using a wire mesh screen as set out above.
  • the man-made vitreous fibres present in the polymeric foam composite must have at least 50% by weight of the fibres with a length less than 100 micrometres as measured by the method above.
  • a larger quantity of fibres can be included in the foamable composition before an unacceptably high viscosity is reached.
  • the compressive strength, fire resistance, and in particular the compression modulus of elasticity of the resulting foam can be improved.
  • ground fibres having such a low length would simply act as a filler, increasing the density of the foam.
  • the length distribution of the man-made vitreous fibres present in the polymeric foam composite or foamable composition is such that at least 50% by weight of the man-made vitreous fibres have a length of less than 75 micrometres, more preferably less than 65 micrometres.
  • At least 60% by weight of the man-made vitreous fibres present in the polymeric foam composite or foamable composition have a length less than 100 micrometres, more preferably less than 75 micrometres and most preferably less than 65 micrometres.
  • the presence of longer man-made vitreous fibres in the polymeric foam composite or foamable composition is found to be a disadvantage in terms of the viscosity of the foamable composition and the ease of mixing. Therefore, it is preferred that at least 80%, or even 85 or 90% of the man-made vitreous fibres present in the polymeric foam composite or foamable composition have a length less than 125 micrometres. Similarly, it is preferred that at least 95%, more preferably at least 97% or 99% by weight of the man-made vitreous fibres present in the polymeric foam composite or foamable composition have a length less than 250 micrometres.
  • the greatest compressive strength can be achieved when at least 90% by weight of the fibres have a length less than 100 micrometres and at least 75% of the fibres by weight have a length less than 65 micrometres.
  • Man-made vitreous fibres having the length distribution discussed above have been found generally to sit within the walls of the cells of the foam composite, without penetrating the cells to a significant extent. Therefore, it is believed that a greater percentage by weight of the fibres in the composite contribute to increasing the strength of the composite rather than merely increasing its density. It is also preferred that at least some of the fibres present in the foam composite material, for example at least 0.5% or at least 1 % by weight, have a length less than 10 micrometres. These very short fibres are thought to be able to act as nucleating agents in the foam formation process. The action of very short fibres as nucleating agents can favour the production of a foam with numerous small cells rather than fewer large cells.
  • the fibres present in the polymeric foam composite or in the foamable composition can be any type of discontinuous man-made vitreous fibres, but are preferably stone fibres.
  • stone fibres have a content by weight of oxides as follows:
  • MgO up to 15% preferably 4 to 10%
  • An advantage of using fibres of this composition in the polymeric foam composite material, especially in the context of polyurethane foams, is that the significant level of iron and alumina in the fibres can act as a catalyst in formation of the foam. This effect is particularly relevant when at least some of the iron in the fibres is present as ferric iron, as is usual and/or when the level of Al 2 0 3 is particularly high such as 15 to 28% or 18 to 23%.
  • An alternative stone wool composition useful in the invention has oxide contents by weight in the following ranges:
  • alumina in fibres of this composition can act as a catalyst in the formation of a polyurethane foam.
  • stone fibres are preferred, the use of discontinuous glass fibres or slag fibres is also possible.
  • the man-made vitreous fibres present in the polymeric foam composite and foamable composition are discontinuous fibres.
  • the term "discontinuous man- made vitreous fibres" is well understood by those skilled in the art. Discontinuous man-made vitreous fibres are, for example, those produced by internal or external centrifugation, for example with a cascade spinner or a spinning cup. Traditionally, fibres produced by these methods have been used for insulation, whilst continuous glass fibres have been used for reinforcement in composites. Continuous fibres (e.g. continuous E glass fibres) are known to be stronger than discontinuous fibres produced by cascade spinning or with a spinning cup (see “Impact of Drawing Stress on the Tensile Strength of Oxide Glass Fibres", J. Am. Ceram.
  • foam composites comprising short, discontinuous fibres have a compressive strength that is at least comparable with foam composites comprising continuous glass fibres of a similar length. This unexpected level of strength is combined with good fire resistance, a high level of thermal insulation and cost efficient production.
  • the further processing will usually involve grinding or milling of the fibres for a sufficient time for the required length distribution to be achieved.
  • the fibres present in the polymeric foam composite and foamable composition have an average diameter of from 1.5 to 7 micrometres.
  • the fibres have an average diameter of from 2 to 6 micrometres, more preferably the fibres have an average diameter of from 3 to 6 micrometres.
  • Thin fibres as preferred in the invention are believed to provide a higher level of thermal insulation to the composite than thicker fibres, but without a significant reduction in strength as compared with thicker fibres as might be expected.
  • the average fibre diameter is determined for a representative sample by measuring the diameter of at least 200 individual fibres by means of the intercept method and scanning electron microscope or optical microscope (1000x magnification).
  • the foamable composition that can be used to produce the polymeric foam composite comprises a foam precursor and man-made vitreous fibres.
  • the foam precursor is a material that either polymerises (often with another material) to form a polymeric foam or is a polymer that can be expanded with a blowing agent to form a polymeric foam.
  • the composition can be any composition capable of producing a foam on addition of a further component or upon a further processing step being carried out.
  • Preferred foamable compositions are those capable of producing polyurethane foams.
  • Polyurethane foams are produced by the reaction of the polyol with an isocyanate in the presence of a blowing agent.
  • the foamable composition comprises, in addition to the man-made vitreous fibres, a polyol as the foam precursor.
  • the foamable composition comprises, in addition to the man-made vitreous fibres, an isocyanate as the foam precursor.
  • the composition comprises a mixture of an isocyanate and a polyol as the foam precursor.
  • foaming can be induced by adding a further component comprising an isocyanate.
  • foam formation can be induced by the addition of a further component comprising a polyol.
  • Suitable polyols for use either as the foam precursor or to be added as a further component to the foamable composition to induce foam formation are commercially available polyol mixtures from, for example, Bayer Material Science, BASF or DOW Chemicals.
  • Commercially available polyol compositions are often supplied as a pre-mixed component that comprises polyol and any or all of catalyst(s), flame retardant(s), surfactants and water, the latter which can act as a chemical blowing agent in the foam formation process. Generally it comprises all of these.
  • Such a pre-formed blend of polyol with additives is commonly known as a pre-polyol.
  • the isocyanate for use either as the foam precursor or to be added as a further component to the foamable composition to induce foam formation is selected on the basis of the density and strength required in the foam composite as well as on the basis of toxicity. It can, for example, be selected from methylene polymethylene polyphenol isocyanates (PMDI), methylene diphenyl diisocyanate (MDI), toluene diisocyanate (TDI), hexamethylene diisocyanate (HDI) and isophorone diisocyanate (IPDI), PDMI or MDI being preferred.
  • PMDI methylene polymethylene polyphenol isocyanates
  • MDI methylene diphenyl diisocyanate
  • TDI toluene diisocyanate
  • HDI hexamethylene diisocyanate
  • IPDI isophorone diisocyanate
  • PDMI PDMI or MDI being preferred.
  • One particularly suitable example is diphenylmethane-4
  • a blowing agent is required.
  • the blowing agent can be a chemical blowing agent or a physical blowing agent.
  • the foamable composition comprises a blowing agent.
  • the blowing agent can be added to the foamable composition together with a further component that induces foam formation.
  • the blowing agent is water.
  • Water acts as a chemical blowing agent, reacting with the isocyanate to form CO 2 , which acts as the blowing gas.
  • the foamable composition comprises water as a blowing agent.
  • the water is usually present in such a foamable composition in an amount from 0.3 to 2 % by weight of the foamable composition.
  • a physical blowing agent such as liquid C0 2 or liquid nitrogen could be included in the foamable composition or added to the foamable composition as part of the further component that induces foam formation.
  • the foamable composition in an alternative embodiment, is suitable for forming a phenolic foam.
  • Phenolic foams are formed by a reaction between a phenol and an aldehyde in the presence of an acid or a base.
  • a surfactant and a blowing agent are generally also present to form the foam. Therefore, the foamable composition could comprise, in addition to the man-made vitreous fibres, a phenol and an aldehyde (the foam precursor), a blowing agent and a surfactant.
  • the foamable composition could comprise as the foam precursor, a phenol but no aldehyde, or an aldehyde but no phenol.
  • foamable compositions suitable for forming polyurethane or phenolic foams are preferred, it is also possible to use foamable compositions suitable for forming polyisocyanurate, expanded polystyrene and extruded polystyrene foams.
  • the polyurethane foam composite is especially a polyisocyanurate foam composite, where the blowing agent is preferably pentane.
  • Pentane has the advantage over other blowing agents that it is more environmentally friendly and cost effective than for instance HFC blowing agents.
  • Pentane can be c-pentane, i-pentane, or n-pentane or a mixture of two or more of these.
  • the choice between c-pentane, i-pentane and n-pentane is dependent on the production method. They are quite different in boiling point, initial thermal conductivity, aged thermal conductivity and price.
  • the preferred pentane in this invention is n-pentane based on the price and aged thermal conductivity.
  • the foamable composition that can be used to make the foam composite used in the invention can contain additives in addition to the foam precursor and the man-made vitreous fibres. When it is desired to include additives in the foam composite, as an alternative to including the additives in the foamable composition comprising man-made vitreous fibres, the additive can be included with a further component that is added to the foamable composition to induce foam formation.
  • the composition or the foam composite may comprise a fire retardant such as expandable powdered graphite, aluminium trihydrate or magnesium hydroxide.
  • the amount of fire retardant in the composition is preferably from 3 to 20% by weight, more preferably from 5 to 15% by weight and most preferably from 8 to 12 % by weight.
  • the total quantity of fire retardant present in the polymeric foam composite material is preferably from 1 to 10%, more preferably from 2 to 8% and most preferably from 3 to 7 % by weight.
  • the foamable composition or foam composite can comprise a flame retardant such as nitrogen- or phosphorus-containing polymers.
  • the fibres used in the polymeric foam composite can be treated with binder, which, as a result, can be included in the composition and the resulting foam composite as an additive if it is chemically compatible with the composition.
  • the fibres used usually contain less than 10% binder based on the weight of the fibres and binder.
  • the binder is usually present in the foamable composition at a level less than 5% based on the total weight of the foamable composition.
  • the foam composite usually contains less than 5% binder, more usually less than 2.5% binder.
  • the man-made vitreous fibres used are not treated with binder.
  • a surfactant usually a cationic surfactant.
  • the surfactant could, alternatively, be added to the composition as a separate component.
  • the presence of a surfactant, in particular a cationic surfactant, in the composition and as a result in the polymeric foam composite material has been found to provide easier mixing and, therefore, a more homogeneous distribution of fibres within the foamable composition and the resulting foam.
  • the composition comprises at least 15% by weight, more preferably at least 20% by weight, most preferably at least 35% by weight of man-made vitreous fibres.
  • the polymeric foam composite material itself preferably comprises at least 10% by weight, more preferably at least 15% by weight, most preferably at least 20% by weight of man-made vitreous fibres.
  • the foamable composition comprises less than 85% by weight, preferably less than 80%, more preferably less than 75% by weight man-made vitreous fibres.
  • the resulting foam composite usually contains less than 80% by weight, preferably less than 60%, more preferably less than 55% by weight man- made vitreous fibres.
  • the polymeric foam composite used in the invention comprises a polymeric foam and man-made vitreous fibres.
  • the foam composite can be formed from the foamable composition as described above. It is preferred that the polymeric foam is a polyurethane foam or a phenolic foam. Polyurethane foams are most preferred due to their low curing time.
  • the first step in the production of the polymeric foam composite material is to form the foamable composition comprising the foam precursor and the mineral fibres.
  • the fibres can be mixed into the foam precursor by a mechanical mixing method such as use of a rotary mixer or simply by stirring. Additives as discussed above can be added to the foamable composition. Once the fibres and foam precursor have been mixed, the formation of a foam can then be induced.
  • the manner in which the foam is formed depends on the type of foam to be formed and is known to the person skilled in the art for each type of polymeric foam. In this respect, reference is made to "Handbook of Polymeric Foams and Foam Technology" by Klempner et al.
  • the man-made vitreous fibres can be mixed with a polyol as the foam precursor.
  • the foamable composition usually also comprises water as a chemical blowing agent. Then foaming can be induced by the addition of an isocyanate.
  • foam formation is induced by the addition of a further component and the further component comprises further man-made vitreous fibres, wherein at least 50% by weight of the further man-made vitreous fibres have a length of less than 100 micrometres.
  • Including man-made vitreous fibres in both the foamable composition and the further component can increase the overall quantity of fibres in the foam composite, by circumventing the practical limitation on the quantity of fibres that can be included in the foamable composition itself.
  • a foamable composition could comprise a polyol, man-made vitreous fibres and water.
  • foaming could be induced by the addition, as the further component, of a mixture of isocyanate and further man-made vitreous fibres, wherein at least 50% of the man-made vitreous fibres have a length of less than 100 micrometres.
  • the mixture of isocyanate and man-made vitreous fibres could constitute the foamable composition
  • the mixture of polyol, water and man-made vitreous fibres could constitute the further component.
  • the quantity of man-made vitreous fibres in the further component is preferably at least 10 % by weight, based on the weight of the further component. More preferably the quantity is at least 20% or at least 30% based on the weight of the further component.
  • the further component comprises less than 80% by weight, preferably less than 60%, more preferably less than 55% by weight man- made vitreous fibres.
  • the polymeric foam composite provides increased compressive strength and resistance to compression to the insulated metal profile. Therefore, preferably the polymeric foam composite has a compressive strength of at least 1500 kPa and a compression modulus of elasticity of at least 60,000 kPa as measured according to European Standard EN 826:1996.
  • the insulated metal profile according to the invention may be produced by first providing a foamable composition as discussed above, inducing foaming to form a polymeric foam composite, and then shaping the polymeric foam composite appropriately to form an insert that can be positioned in the relevant channel in the profile, followed by subsequently inserting this shaped polymeric foam composite insert into the channel. Generally the shaped insert is adhered to the inner surface of the channel, for instance using adhesive.
  • the metal profile is chemically cleaned or mechanically treated prior to addition of the foam composite core, in order to effect better adhesion of the foam composite core to the metal profile.
  • the polymeric foam composite core is formed in situ in the channel.
  • a foamable composition as discussed above is provided and this foamable composition is introduced into the channel in an amount sufficient that when foaming has been completed the polymeric foam composite will take up the required volume. Foaming is then induced and the foamable composition foams and generally expands to fill the channel. The resultant foam composite generally comes into contact with substantially all of the inner surface of the channel and adheres to it.
  • Figure 1 a shows a cross-section through an insulated U-profile according to the invention.
  • Figure 1 b shows a cross-section through a further insulated U-profile according to the invention.
  • Figure 1 c shows a cross-section through an insulated profile according to the invention having a rectangular enclosed channel.
  • Figure 1d shows a cross-section through a further insulated profile according to the invention having an enclosed channel of circular cross-section.
  • Figure 2a shows a perspective view of the insulated profile of Figure 1a.
  • Figure 2b shows a perspective view of the insulated profile of Figure 1 b.
  • Figure 2c shows a perspective view of the insulated profile of Figure 1 c.
  • Figure 2d shows a perspective view of the insulated profile of Figure 1d.
  • Figure 3 shows samples described in Examples 1 and 2 below prior to heating.
  • Figure 4 shows samples used in Examples 1 and 2 below after two hours of heating.
  • Figure 5 shows samples used in Examples 1 and 2 below after 20 hours of heating.
  • Figure 6 is an environmental scanning electron microscope image of a polyurethane foam composite material as used according to the invention.
  • a metal profile 1 according to the invention.
  • This has a single channel 2 filled with polymeric foam composite core 3 along its length.
  • the channel has a U-shape cross-section.
  • the metal profile is preferably made of aluminium.
  • Figures 1 b and 2b show a similar profile 1 , in cross-section and perspective view, with the difference that in Figures 1 a and 2a, one side of the profile has an additional fin 4 as a distance measure.
  • Figures 1 c and 2c show cross-sectional and perspective views respectively of a further insulated metal profile 1 according to the invention.
  • the profile defines an enclosed channel 2, of substantially square cross-section. This channel is also substantially filled by the polymeric composite foam core 3 along its length.
  • Figures 1 d and 2d show a cross-sectional and perspective view respectively of a further insulated profile 1 according to the invention.
  • the channel 2 is fully enclosed along its length and is filled along its length with the polymeric foam composite 3.
  • the cross-section in this case is substantially circular.
  • FIG. 3 there is shown an image of two samples described in Examples 1 and 2 below prior to heating.
  • the profile is U-shaped and made of aluminium, having a metal thickness of 0.5mm.
  • the profile for Example 1 is filled with polyurethane foam made according to Example 1 and the sample for Example 2 is filled with the polymeric foam composite material used in the present invention.
  • FIG. 4 there is shown an image of the same two samples used in Examples 1 and 2 below after two hours of heating.
  • the PUR foam has slipped from the walls of the aluminium profile due to shrinkage, whereas the polymeric foam composite material used in the present invention has retained its shape.
  • Figure 5 shows an image of the same two samples used in Examples 1 and 2 below after 20 hours of heating. It can be seen that the polyurethane foam has an even larger detachment from the aluminium profile and exhibits sever shrinkage, where the polymeric foam composite material used in the present invention after 20 hours of heating still has retained its shape.
  • Figure 6 is an environmental scanning electron microscope image of a polyurethane foam composite material as used according to the invention, in which the fibres have a length distribution such that 95% by weight of the fibres have a length below 100 micrometres and 75% by weight of the fibres have a length below 63 micrometres. The composite contains 45% fibres by weight of the composite.
  • the instrument used was ESEM, XL 30 TMP (W), FEI/Philips incl. X-ray microanalysis system EDAX. The sample was analysed in low vacuum and mixed mode (BSE/SE).
  • the image shows the cellular structure of the foam and demonstrates that the man-made vitreous fibres generally sit in the walls of the cells of the foam without penetrating into the cells themselves to a significant extent.
  • An elongate U-shaped aluminium profile measuring 75 mm in width and 20 mm in height was prepared and cleaned with acetone.
  • the metal thickness of the aluminium was 0.5 mm.
  • 100 g of a commercially available composition of diphenylmethane-4,4'-diisocyanate and isomers and homologues of higher functionality, and 100 g of a commercially available polyol formulation were mixed by propellers for 20 seconds at 3000 rpm. The material was then transferred into the aluminium profile and allowed to foam. The next day, 100 mm of the profile (as shown in Figure 3) was cut and placed in a heating cupboard at 200 °C.
  • Example 1 100 g of the same commercially available polyol formulation as used in Example 1 was mixed with 200 g ground stone wool fibres with over 50% having a length less than 64 micrometers. Then 100 g of the commercially available composition of diphenylmethane-4,4'-diisocyanate was added and the mixture was mixed by propellers for 20 seconds at 3000 rpm for making the polymeric foam composite material for used in this invention. Samples similar to the samples in Example 1 were prepared (see Figure 3) and tested similarly. The test clearly showed that the polymeric foam composite material was firmly attached to the entire aluminium surface and had retained its shape after both 2 hours ( Figure 4) and 20 hours of heating (see Figure 5).
  • 100.0 g of the same commercially available polyol formulation as used in Example 3 was mixed with 200.0 g ground stone wool fibres, over 50% of which have a length less than 64 micrometres, for 10 seconds. Then 100.0 g of the commercially available composition of diphenylmethane-4,4'-diisocyanate was added and the mixture was mixed by propellers for 20 seconds at 3000 rpm. The material was then placed in a mold to foam, which took about 3 min. The following day, the sample was weighed to determine its density and the compression strength and compression modulus of elasticity were measured according to European Standard EN 826:1996.
  • 100.0 g of the same commercially available polyol formulation as used in Examples 3 and 4 was mixed for 10 seconds with 50.0 g stone fibres having a different chemical composition from those used in Example 4 and having an average length of 300 micrometres.
  • 100.0 g of the commercially available composition of diphenylmethane-4,4'-diisocyanate was added.
  • the mixture was then mixed by propellers for 20 seconds at 3000 rpm.
  • the material was placed in a mold to foam, which takes about 3 min. The following day, the sample was weighed to determine its density and the compression strength and compression modulus of elasticity were measured according to European Standard EN 826:1996.
  • Example 5 was repeated, but the fibres were ground such that greater than 50% of the fibres had a length less than 64 micrometres. Following this grinding it became possible to mix 200g of the fibres with the polyol mixture.
  • Compression modulus of elasticity 1 15000 kPa.
  • the quartz sand used had a particle size up to 2mm.
  • expanding graphite was included as a fire retardant.
  • the test involved measuring the height of a flame from each composite under controlled conditions. The results were as follows:

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Abstract

Cette invention concerne un profilé métallique isolé, comprenant : un profilé métallique allongé (1) définissant au moins un canal longitudinal (2), ledit canal longitudinal contenant un noyau (3) fait d'un matériau composite à base de mousse polymère comprenant une mousse polymère et des fibres vitreuses synthétiques discontinues, au moins 50 % en masse desdites fibres vitreuses synthétiques présentes dans le matériau composite en mousse présentant une longueur inférieure à 100 micromètre.
PCT/EP2014/053156 2013-02-18 2014-02-18 Profilé métallique isolé et sa production WO2014125126A1 (fr)

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Cited By (1)

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DE102019208776A1 (de) * 2019-06-17 2020-12-17 NWI Entwicklung Süd GmbH Solarmodultraggerüst und Solaranlage mit einem Hohlprofil sowie Verfahren zum Herstellen eines Solarmodultraggerüsts

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DE2722824A1 (de) 1977-05-20 1978-11-23 Fuchs Fa Otto Verfahren zum biegen von hohlprofilen
DE3621765A1 (de) * 1986-06-28 1988-01-07 Hueck Fa E Verwendung von zu polyurethanen ausreagierenden giessmassen zur herstellung von isolierstegen fuer metall-verbundprofile
US6406078B1 (en) 1994-05-19 2002-06-18 Henkel Corporation Composite laminate automotive structures
DE102004008201A1 (de) * 2004-02-18 2005-09-01 Basf Ag Verfahren zur Herstellung füllstoffhaltiger Schaumstoffplatten
US20060234034A1 (en) * 2001-09-13 2006-10-19 Thomas Tschech Extrusion profile and method of production thereof

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DE2722824A1 (de) 1977-05-20 1978-11-23 Fuchs Fa Otto Verfahren zum biegen von hohlprofilen
DE3621765A1 (de) * 1986-06-28 1988-01-07 Hueck Fa E Verwendung von zu polyurethanen ausreagierenden giessmassen zur herstellung von isolierstegen fuer metall-verbundprofile
US6406078B1 (en) 1994-05-19 2002-06-18 Henkel Corporation Composite laminate automotive structures
US20060234034A1 (en) * 2001-09-13 2006-10-19 Thomas Tschech Extrusion profile and method of production thereof
DE102004008201A1 (de) * 2004-02-18 2005-09-01 Basf Ag Verfahren zur Herstellung füllstoffhaltiger Schaumstoffplatten

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KLEMPNER: "Handbook of Polymeric Foams and Foam Technology"
SHAMOV I V ET AL: "Anwendung zerkleinerter Glasfasern als modifizierender Zusatz fur Polyurethanhartschaumstoffe", PLASTE UND KAUTSCHUK, DEUTSCHER VERLAG FUER GRUNDSTOFFINDUSTRIE GMBH, DE, vol. 26, no. 1, 1 January 1979 (1979-01-01), pages 23 - 25, XP008150045, ISSN: 0048-4350 *

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102019208776A1 (de) * 2019-06-17 2020-12-17 NWI Entwicklung Süd GmbH Solarmodultraggerüst und Solaranlage mit einem Hohlprofil sowie Verfahren zum Herstellen eines Solarmodultraggerüsts

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