WO2015082691A1 - Procédé de production d'un élément composite en sandwich - Google Patents

Procédé de production d'un élément composite en sandwich Download PDF

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Publication number
WO2015082691A1
WO2015082691A1 PCT/EP2014/076743 EP2014076743W WO2015082691A1 WO 2015082691 A1 WO2015082691 A1 WO 2015082691A1 EP 2014076743 W EP2014076743 W EP 2014076743W WO 2015082691 A1 WO2015082691 A1 WO 2015082691A1
Authority
WO
WIPO (PCT)
Prior art keywords
reaction mixture
polyurethane reaction
composite component
sandwich composite
polyurethane
Prior art date
Application number
PCT/EP2014/076743
Other languages
German (de)
English (en)
Inventor
Salvatore Cucchiara
Original Assignee
Heyform Bramsche Gmbh
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
Priority claimed from DE102013020488.7A external-priority patent/DE102013020488A1/de
Application filed by Heyform Bramsche Gmbh filed Critical Heyform Bramsche Gmbh
Publication of WO2015082691A1 publication Critical patent/WO2015082691A1/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
    • B29C44/04—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 consisting of at least two parts of chemically or physically different materials, e.g. having different densities
    • B29C44/0461—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 consisting of at least two parts of chemically or physically different materials, e.g. having different densities by having different chemical compositions in different places, e.g. having different concentrations of foaming agent, feeding one composition after the other

Definitions

  • the present invention relates to a method for producing a sandwich composite component according to the preamble of claim 1 and to a sandwich composite component according to the preamble of claim 15.
  • the loading floor of the trunk, the parcel shelf or another flat interior component is regularly executed as a composite panel in a sandwich construction.
  • a composite panel has several layers.
  • the rigidity stems regularly from the outer cover layers, between which the core layer acts as a spacer and regularly has a ngergees specific weight than the outer layers.
  • a carpet layer is provided as a lamination on at least one of the outer layers.
  • such an inner component has insertion elements such as hinge pins, snappers, locks or the like for arrangement and fastening in the motor vehicle. Further possible such insert elements on an inner component are lashing point troughs and rails, loading protection edges etc.
  • a sandwich composite component 1 especially for a loading floor in a motor vehicle with a core layer, which consists essentially of paper honeycomb.
  • This core layer has on both sides to produce the desired stiffness and hardness on a cover layer of foamed polyurethane with a fiber material.
  • such a sandwiched composite member having a core layer of paper honeycomb also has a number of disadvantages.
  • Another problem is that the attachment of the above functional elements on the one hand consuming and on the other hand, the Papi erwabenkem is not well suited to give these insert elements hold so that this hold must be provided substantially completely by the cover layer.
  • the paper honeycomb core is also particularly sensitive to the ingress of moisture. For this, even minor damage to the cover layer suffice. Ingress of moisture in turn can lead to both swelling of the paper honeycomb and mold formation.
  • DE 103 10 368 A1 also shows a sandwich composite component in which both the core layer and the cover layers are formed from polyurethane foam.
  • the cover layers are foamed by means of a robot on the core layer, which requires that the core layer is already present as a solid foam.
  • the application of the cover layer shown here therefore requires the completion of the production of the core layer as a previous step.
  • the problem of the invention is to improve the production of such a sandwich composite component in such a way that both work steps are saved and, at the same time, the disadvantages arising from the non-uniform honeycomb structure with regard to contouring possibility, the fastening of insert elements and the Uniformity at the edge of the component to be corrected.
  • Essential to the invention is the recognition that a particularly flexible shaping of a cover layer with a core layer without the mentioned disadvantages of the honeycomb structure can be achieved by applying a polyurethane reaction mixture for the cover layer to the tool halves of a die-forming tool, and After closing the mold embossing tool another polyurethane reaction mixture is introduced into the mold embossing tool, so that the two polyurethane reaction mixtures crosslink at least partially simultaneously and thus also with each other by foaming. In this way, a particularly stable connection between the cover layer and the core layer is formed. At the same time, the process is inexpensive and allows the production of a lightweight sandwich composite component.
  • the contour of the sandwich composite component is in principle freely selectable.
  • the resulting core layer is free of unwanted voids, gaps or weak points and can easily adapt to the production spatially. Insertion elements can be very flexible and at the same time easily taken into account in this process, wherein the reliable connection with the core layer also ensures a good grip of the insert elements.
  • the acoustic effectiveness of the sandwich composite component can be adjusted.
  • the edge regions of the sandwich composite component can be made uniform in the same manufacturing process and provided with the cover layer.
  • a core layer of polyurethane is also more temperature resistant than paper honeycomb material.
  • the preferred embodiments of the dependent claims 2 to 5 relate to further details for introducing and curing the respective polyurethane reaction mixture for the core and the cover layer.
  • the dependent claim 7 relates to the mechanical reinforcement of the cover layer by the provision of fibers, whereby the mechanical properties of the cover layer can be flexibly adjusted.
  • the preferred embodiments of the dependent claims 9 and 10 describe possibilities for realizing desired particular acoustic properties of the sandwich composite component (1).
  • the dependent claims 1 1 to 13 describe the introduction of insert elements in the manufacturing process.
  • the dependent claim 14 provides a pivotable section on at least one tool half, so that a flanging of the side edges of the sandwich component is made possible for a laminating layer, such as a carpet layer.
  • FIG. 1 is a schematic side view of a form embossing tool during a first, preferably provided step of a proposed method
  • FIG. 2 shows a schematic side view of the stamping tool of FIG.
  • FIG. 3 is a schematic side view of the die stamping tool of FIG.
  • FIG. 4 is a schematic side view of the die stamping tool of FIG.
  • 5a is a schematic side view of a first embodiment of a proposed sandwich composite component with a lashing eye and a vent as insert elements
  • 5b) is a schematic side view of a second embodiment of a proposed sandwich composite component with a collapse area
  • 6a-b is a schematic side view of a form embossing tool with pivotable sections during two steps of a proposed method
  • Fig. 7a is a schematic side view of a third Ausruhrungsbeispiels a proposed sandwich composite component with a side rail and an optical waveguide insert elements and
  • Fig. 7b is a schematic side view of a fourth embodiment of a proposed sandwich composite component with a toothed lashing rail as insert element.
  • the proposed method comprises applying a first polyurethane reaction mixture 2 to mold halves 3a, b of a die-embossing tool 4 to form a cover layer 5.
  • the first polyurethane reaction mixture 2 regularly comprises an isocyanate component and a polyol component, whereby a polyurethane foam is formed in a manner known per se in a foaming crosslinking reaction. This networking is accompanied by foaming and hardening.
  • the resulting polyurethane foam which may also be referred to as a first polyurethane foam, then constitutes the cover layer 5 in the present sense.
  • the polyurethane reaction mixture 2 may comprise further constituents in a manner known per se, for which further examples are discussed below. As shown in FIGS.
  • the tool halves 3a, b can also be shaped parts of the die 4, which can have different sizes and / or shapes, so that they do not have to form mathematically exact halves of the die 4.
  • each individual mold half 3a, b may also be multi-part, as will be explained in more detail below with respect to FIG. 6.
  • the proposed method further includes closing the mold embossing tool 4, which takes place in the transition from FIG. 2 to FIG. 3. It should be noted that even if the crosslinking of the polyurethane reaction mixture 2 already begins here, at least this does not exert any counter-pressure to close the mold-stamping tool 4 and thus the mold-stamping tool 4 can be closed without applying a pressing force.
  • the proposed method is characterized in that subsequently a second polyurethane reaction mixture 6 for forming a core layer 7 is introduced into a cavity 8 of the form-stamping tool 4.
  • the second polyurethane reaction mixture 6 may be identical to the first polyurethane reaction mixture 2, but preferably the second polyurethane reaction mixture 6 will differ from the first polyurethane reaction mixture 2 in order to achieve different properties in the core layer 7, the Ratio to the second polyurethane reaction mixture 6 is mutually the same as that between the first polyurethane reaction mixture 2 and the cover layer 4.
  • the second polyurethane reaction mixture 6 may comprise further constituents in addition to an isocyanate component and a polyol component. In particular, that can second polyurethane reaction mixture 6 be enriched with carbon blends.
  • the resulting from the second polyurethane reaction mixture 6 foam may also be referred to as a second polyurethane foam.
  • the cavity 8 is formed by the closing of the die 4 and in particular by the tool halves 3a, b. Specifically, the second polyurethane reaction mixture 6 is introduced through a supply line 9 into the cavity 8.
  • the proposed method is further characterized in that the first polyurethane reaction mixture 2 and the second polyurethane reaction mixture 6 at least partially co-foaming and enter into a compound.
  • the respective crosslinking process overlaps, so that the crosslinking process of the one polyurethane reaction mixture does not start until the crosslinking of the other polyurethane reaction mixture has been completed.
  • the connection between the first polyurethane reaction mixture 2 and the second polyurethane reaction mixture 6 already arises from the fact that - as shown in FIG. 3, these occur during their at least partially simultaneous
  • the die-stamping tool 4 has heating elements 10 with which the temperature conditions during manufacture and in particular for crosslinking can be set and controlled. Furthermore, the die-stamping tool 4 also has a discharge line 11, through which the escape of material from the cavity 8 can be permitted during the intumescent cross-linking.
  • FIG. 4 illustrates the state after completion of the crosslinking of the first polyurethane reaction mixture 2 and of the second polyurethane reaction mixture 6, whereby the cover layer 5 and the core layer 7 have been formed.
  • the intumescent crosslinking is accompanied by a volume expansion of the respective polyurethane reaction mixture, so that the cavity 8 is substantially completely filled, except for possibly existing further structures in the mold-embossing tool 4 - which will be discussed below.
  • the cover layer 5 is arranged on both surface sides of the core layer 7 - and also on the edge sides of the core layer 7 - and thus basically a distinction could be made between an upper and a lower cover layer 5, here and below is always a single one
  • Top layer 5 the speech, wherein the cover layer 5 on all sides as far as there - the core layer 7 is meant.
  • the stamping tool 4 further comprises a suction device 12, which is arranged in the illustration on the upper mold half 3a. This is used to suck the applied to this mold half 3a first polyurethane Christsgemi cal 2, including a film, not shown here on the horrurgil fte 3a is arranged.
  • the second polyurethane reaction mixture 6 - as shown in FIG. 3 - is poured liquid into the cavity 8. This means that preferably the second polyurethane reaction mixture 6 is still substantially uncrosslinked. In order to take into account the volumetric expansion during the crosslinking, preferably the polyurethane reaction mixtures 2, 6 do not completely fill the cavity 8, so that-at least immediately-any desired gases remain in the cavity 8 after pouring.
  • the crosslinking of the first polyurethane reaction mixture 2 begins before the crosslinking of the second polyurethane reaction mixture 6.
  • the crosslinking of the first polyurethane reaction mixture 2 and the second polyurethane reaction mixture 6 is completed substantially simultaneously.
  • the first reaction mixture 2 is pressed outwardly from the second reaction mixture 6 to the tool halves 3a, b. Accordingly, it is preferred that the first polyurethane reaction mixture 2 and the second polyurethane reaction mixture 6 form a frictional connection during crosslinking to the cover layer 5 and to the core layer 7.
  • the second polyurethane reaction mixture 6 exerts a surface pressure on the first polyurethane reaction mixture 2 during crosslinking.
  • the method described makes it possible to cover the core layer 7 essentially from all sides of the cover layer 5.
  • the cavity 8 and the sandwich composite component 1 are substantially plate-shaped.
  • the cover layer 5 also covers the edge sides 13 of the sandwich composite component 1.
  • the cover layer 5 can substantially completely cover the edge sides 13 of the sandwich composite component 1.
  • fibers can be used for reinforcement. It is therefore preferred that to the first polyurethane reaction mixture 2, a fiber material is applied to the tool halves 3a, b and the cover layer 5 is formed by the first polyurethane reaction mixture 2 and the fiber material fiber composite cover layer.
  • the proposed method also makes it possible to integrate the lamination process in a simple manner. This is preferably done by applying a laminating layer 14 to at least one mold half 3b for connection to the first polyurethane reaction mixture 2 during the crosslinking of the first polyurethane reaction mixture 2.
  • FIG. 1 shows how this laminating layer 14, which, for example, a carpet layer may be applied to the tool half 3b prior to the application of the first polyurethane reaction mixture 2.
  • a Such Kaschierlage 14 are applied to the other tool half 3a.
  • a pore property of the core layer 7 is determined for a given property profile of the sandwich composite component 1.
  • This pore property may in particular be a pore size.
  • the pore property is determined by an additive for the second polyurethane reaction mixture 6, which may be above all a liquid additive, which can dissolve in particular in the second polyurethane reaction mixture 6.
  • the pore property can be determined by a mixing ratio of the second polyurethane reaction mixture 6, wherein in particular a mixing ratio of their 1 soc yanatko mponente and their polyol component comes into question.
  • the predefined property profile may be an acoustic property profile, in which case in particular a property profile for a given sound insulation and / or a predetermined sound attenuation may be provided.
  • the second polyurethane reaction mixture 6 in particular a solid filler for a given property profile.
  • a solid filler for a given property profile.
  • fibers and in particular glass fibers may be provided or a heavy layer preferably formed of plastic.
  • a granular core layer 7a formed with such a filler is shown in FIG. 7a.
  • the property profile is preferably an acoustic, especially as described above, and / or a mechanical one.
  • the filler remains after crosslinking of the second polyurethane reaction mixture 6 in the core layer 7. This means z. B.
  • an insert element 15 may be arranged in the mold embossing tool 4 prior to introduction of the second polyurethane reaction mixture 6 such that the insert element 15 is continuous with the second polyurethane reaction mixture 6 and after its crosslinking with the core layer 7, optionally in the presence of intermediate layers , connected is. This means that no macroscopic, so beyond the foam bubbles, free spaces around the insert element 15 are present.
  • the insert element 15 is then also connected to the cover layer 5. In this way, a good grip is ensured because the core layer 7 in particular does not have the inhomogeneities of about paper honeycomb.
  • the insert element 15 is inelastic.
  • a position of the insert element 15 is predetermined and that the insert element 15 during insertion and during the crosslinking of the second polyurethane reaction mixture 6 maintains the predetermined position.
  • the insert element 15 is thus not moved by the second polyurethane reaction mixture 6 in the cavity 8 or even washed away.
  • a vent 16 and a lashing eye 17 are shown in Fig. 5a as such insert elements 15, a vent 16 and a lashing eye 17 are shown. If, as preferred and illustrated for the lashing eye 17, that insertion element 15 is repeatedly mi mi the cover layer 5 in conjunction, which can also be described as penetrating the core layer 7, a particularly good grip is guaranteed. This is further ensured by the likewise preferred Christmas tree structure of an insert element 15, here the lashing eye 17.
  • insertion elements 15 are the side rail 18 shown in FIG. 7a and the toothed lashing rail 19 shown in FIG. 7b. These also realize that preferred embodiment of the insertion element 15, in which the insertion element 15 openings 20 for receiving the first polyurethane reaction mixture 2 and / or the second polyurethane reaction mixture 6, whereby the hold of the insert member 15 is further improved.
  • the egg is geelement 15 an optical waveguide 1 5a, which is also shown in Fig. 7a.
  • a further binding material which may likewise be a polyurethane reaction mixture, can be applied to the insert element 15 for connection to the second polyurethane reaction mixture 6 during the crosslinking of the second Polyur- ethane reaction mixture.
  • a laminating layer 14 provided in principle for one main surface of the sandwich composite component 1 does not extend completely over only one edge side 13 of the sandwich composite component 1, but even at least partially on the opposite one Main surface is arranged.
  • This arrangement of the laminating layer 14 may also be referred to as flanging.
  • the liner 14 is applied to the pivotable portion 21 a, b.
  • a proposed sandwich composite component 1 which is especially adapted for use in a motor vehicle and is shown in particular in FIGS. 5 a b) and 7 a b), has a cover layer 5 with a first polyurethane foam and a core layer 7 with a second polyurethane foam on.
  • the proposed sandwich composite component 1 is characterized in that the first polyurethane foam and the second polyurethane foam have at least partially co-foaming and thereby entered into a connection.
  • the proposed composite sandwich component I has been prepared by a proposal according to the method.
  • the embodiments and features described for the proposed method apply mutatis mutandis to the proposed sandwich composite component 1, wherein in particular the first polyurethane foam by crosslinking the first polyurethane reaction mixture 2 and the second polyurethane foam by crosslinking the second polyurethane reaction mixture 6 has emerged.
  • the sandwich composite component 1 comprises a, preferably inelastic, insert element 15 and that the insert element 15 is connected to the core layer 7 in a continuous manner, optionally in the presence of intermediate layers.
  • the insert element 15 may be connected to the cover layer 5.
  • a largely free contouring of the surface of the sandwich composite component 1 can be made. This possibility in turn can also be used to design mechanical properties of the sandwich composite component 1.
  • Fig. 5b shows a corresponding embodiment.
  • the composite sandwich component 1 has a collapse area 22 with respect to a collapse direction 23.
  • Such a collapsing region 22 can in particular - and as shown - be realized in that the collapse region 22 has a wave-like or rectangular comb course of the cover layer 5 with respect to a thickness of the sandwich composite component 1.
  • the wave or rectangular shapes preferably break before a break of the sandwich composite component 1 occurs elsewhere.
  • a sandwich composite component 1 it is possible to use such a sandwich composite component 1 as a loading floor, thereby designing the collapsing area 22 and the collapse direction 23 for a rear crash of the motor vehicle.

Landscapes

  • Laminated Bodies (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)

Abstract

L'invention concerne un procédé de production d'un élément composite en sandwich (1) destiné notamment à être utilisé dans un véhicule à moteur, comprenant l'application d'un premier mélange réactionnel de polyuréthane (2) sur des moitiés (3a, b) d'un moule d'estampage (4) pour former une couche de recouvrement (5) et comprenant la fermeture du moule d'estampage (4). Le procédé est caractérisé en ce qu'ensuite un deuxième mélange réactionnel de polyuréthane (6) est introduit dans une cavité (8) du moule d'estampage (4) pour former une couche formant âme (7) et en ce que le premier mélange réactionnel de polyuréthane (2) et le deuxième mélange réactionnel de polyuréthane (6) se réticulent en moussant, au moins en partie simultanément, engendrant ainsi une liaison. L'invention concerne un élément composite en sandwich (1), destiné notamment à être utilisé dans un véhicule à moteur et comprenant une couche de recouvrement (5) comportant une première mousse de polyuréthane, et une couche formant âme (7) comportant une deuxième mousse de polyuréthane. L'élément composite en sandwich est caractérisé en ce que la première mousse de polyuréthane et la deuxième mousse de polyuréthane se réticulent au moins en partie simultanément, engendrant ainsi une liaison.
PCT/EP2014/076743 2013-12-06 2014-12-05 Procédé de production d'un élément composite en sandwich WO2015082691A1 (fr)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
DE102013020100 2013-12-06
DE102013020100.4 2013-12-06
DE102013020488.7A DE102013020488A1 (de) 2013-12-11 2013-12-11 Verfahren zum Herstellen eines Sandwich-Verbundbauteils
DE102013020488.7 2013-12-11

Publications (1)

Publication Number Publication Date
WO2015082691A1 true WO2015082691A1 (fr) 2015-06-11

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PCT/EP2014/076743 WO2015082691A1 (fr) 2013-12-06 2014-12-05 Procédé de production d'un élément composite en sandwich

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WO (1) WO2015082691A1 (fr)

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS59138421A (ja) * 1983-01-29 1984-08-08 Taisei Kako Kk 一体的な接続用ア−ムを持つ合成樹脂製フロ−トの製造方法
DE3701953A1 (de) * 1987-01-23 1988-08-04 Klepper Beteiligungs Gmbh & Co Bootskoerper und verfahren zu dessen herstellung
US5989699A (en) * 1997-12-01 1999-11-23 Woodbridge Foam Corporation Foam composite material comprising a first foam having an uncontoured surface, and a second, different foam fixed to the first foam at its uncontoured surface
DE10310368A1 (de) 2003-03-10 2004-10-07 Webasto Vehicle Systems International Gmbh Ladeboden
WO2007066899A1 (fr) * 2005-11-02 2007-06-14 Jang Won Park Procede de moulage par injection

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS59138421A (ja) * 1983-01-29 1984-08-08 Taisei Kako Kk 一体的な接続用ア−ムを持つ合成樹脂製フロ−トの製造方法
DE3701953A1 (de) * 1987-01-23 1988-08-04 Klepper Beteiligungs Gmbh & Co Bootskoerper und verfahren zu dessen herstellung
US5989699A (en) * 1997-12-01 1999-11-23 Woodbridge Foam Corporation Foam composite material comprising a first foam having an uncontoured surface, and a second, different foam fixed to the first foam at its uncontoured surface
DE10310368A1 (de) 2003-03-10 2004-10-07 Webasto Vehicle Systems International Gmbh Ladeboden
WO2007066899A1 (fr) * 2005-11-02 2007-06-14 Jang Won Park Procede de moulage par injection

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