CN1929989A - 复合构件 - Google Patents

复合构件 Download PDF

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CN1929989A
CN1929989A CNA2005800071468A CN200580007146A CN1929989A CN 1929989 A CN1929989 A CN 1929989A CN A2005800071468 A CNA2005800071468 A CN A2005800071468A CN 200580007146 A CN200580007146 A CN 200580007146A CN 1929989 A CN1929989 A CN 1929989A
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sandwich
composite component
skin
sandwich layer
thermoplastic
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CN100486801C (zh
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R·维尔肯斯
R·埃尔克伦茨
A·拉梅克
M·克洛克
K·科内荣
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Covestro Deutschland AG
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Bayer MaterialScience AG
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Abstract

本发明涉及一种基于夹层结构的复合构件，至少由下列组成：(a)两外层(3，3’)，其各自独立地由各至少一种由金属、塑料、玻璃、天然物质和/或碳制成的膜、板、纤维层和/或泡沫塑料组成，和(b)置于外层(3，3’)之间的芯层，其由含大量空腔的金属、塑料、天然物质和/或纸制成。铸塑树脂体系至少部分贯穿该外层(3，3’)和芯层，并通过压制使外层(3，3’)和芯层(4)相连接。该复合构件的特征在于，该外层(3，3’)在夹层结构的至少一个区(5，5’)相互压制，并且在压制区(5，5’)的该夹层结构由热塑性塑料所包封。

Description

复合构件
本发明涉及一种具有夹层结构的复合构件，其至少由置于两外层之间的芯层组成。铸塑树脂体系至少部分贯穿所述层，并且所述层经压制相互粘合。本发明还涉及制备这种复合构件的方法。
如由EP 1319503 A已知一种具有夹层结构的轻质复合构件，其由具有蜂窝结构或波型结构的芯层如纸、铝或塑料和由纤维层如天然纤维、玻璃纤维、塑料纤维或碳纤维制成的下外层和上外层组成。由于其在小壁厚下的低面积重量和高抗弯强度，例如可在汽车制造中用作内贴衬。该下外层和上外层的纤维层例如用双组分聚氨酯(PUR)体系润湿，该体系部分或全部渗入芯层中。该例如可易于发泡的PUR体系提供了外层与芯层的成型和粘合。
该夹层复合构件按模压法制造。由芯层和外层制成的该夹层结构的两面表面喷涂以双组分PUR体系，并引入到通常加热到60-160℃，优选120-140℃的模具中并经压制。脱模和冷却后，该复合构件按需进行如冲压、铣削或包覆。
螺纹连接、局部金属增强、连结部件、紧固部件等的整合的可能性是有限的。例如在压制工具中制备复合构件时，可相应定位***件，并在压制时通过发泡的和硬化的PUR体系与复合构件粘合。该***件也可完全封入复合构件中，这时将外层如纤维层置于该***件上面，并在压制时压在***件上。
另外还已知，将如由塑料制成的模制部件通过熔焊连接在轻质复合构件上。但这是较耗费的，因为首先要单独制备模制部件，然后将其引入熔焊工具中进行熔焊。此外，熔焊连接的质量与所用的材料很有关系。
再则还已知，这类夹层复合构件用易流动的材料如聚氨酯进行包封。该用聚氨酯注塑的复合构件的缺点是有较低的刚度和强度。此外，用交联性的PUR树脂体系有针对性地注塑该复合构件的各区域是很耗费的。在注塑的PUR中形成毛刺还需要耗费性的后加工。最后，注塑的PUR表面对某些应用不能满足光学要求，并不能着色。
本发明的目的在于，在现有技术已知的具有夹层结构的轻质复合构件基础上提供一种复合构件，其适于借助于注塑法整合功能部件和模制部件，特别是由热塑性塑料制成的模制部件。
本发明主题是一种基于夹层结构的复合构件，其至少由下列组成：
(a)两外层，其各自独立地分别由至少一种由金属、塑料、玻璃、天然物质和/或碳制成的膜、板、纤维层和/或泡沫塑料组成，和
(b)置于外层之间的芯层，其由含大量空腔的金属、塑料、天然物质和/或纸制成，
其中，铸塑树脂体系至少部分贯穿外层和芯层，并通过压制使外层和芯层相连接，其特征在于，至少在一部分夹层结构区对外层进行相互压制，并且在压制区的夹层结构用热塑性塑料包封。
本发明的复合构件至少由三层组成：一层芯层和芯层两面的两外层。由多层芯层和由多层外层组成的结构也是可能的。芯层由金属、塑料、天然物质和/或纸构成。优选的金属是铝、镁和它们的合金。优选的塑料是聚酰胺、聚酯、聚碳酸酯、聚丙烯、聚苯乙烯、ABS、聚酰胺-酰亚胺(PAI)和其混合物。塑料可为经增强的或未经强的、经填充的或未经填充的。天然物质的实例是木材、亚麻、剑麻、黄麻、***。在本发明中所述的纸意指各类纸，如多层纸，如硬纸板或经树脂浸渍过的纸。
作为主要特征，本发明复合构件的芯层含大量的空腔。该空腔可呈任意几何形状。空腔可以是例如角形的或圆形的通道、孔或气泡。该空腔可呈规则或不规则排列。优选芯层具有波形的、角形的、蜂窝状或海绵类的外型。芯层例如可以是波纹金属板或波纹硬纸板。类似于波纹金属板或波纹硬纸板，芯层也可是角形的而不是波形的，例如具有矩形或三角形形状。此外，类似于波纹金属板或波纹硬纸板，芯层也可由塑料制成。角形或波形的塑料型材例如可是挤压成型的。例如可应用多壁板作为由塑料制成的芯层。
芯层的厚度优选为5-50mm。由于大量的空腔，芯层的重量相对于其厚度是小的。其密度优选为10-1000kg/m3。
本发明的复合构件的芯层两面的外层各自独立地由金属、塑料、玻璃、天然物质和/或碳构成。该外层是膜、板、纤维层和/或泡沫塑料。纤维层可以是例如网、织物、针织物、编织物、无纺织物或毡。适于外层的优选金属是铝、镁和它们的合金。优选的塑料是聚酰胺、聚酯、聚碳酸酯、聚丙烯、聚苯乙烯、ABS、PAI和其混合物。适于外层的天然物质例如是亚麻、剑麻、黄麻和***。芯层两面的外层可以是相同的或不同的。
外层厚度优选为0.1-2mm。该外层的面积重量优选为225-1200g/m2。
铸塑树脂体系至少部分贯穿本发明复合构件的面层和芯层。这意味着该铸塑树脂体系部分或全部充填芯层的空腔。如果外层由纤维层或泡沫塑料构成，则该铸塑树脂体系同样也贯穿外层的纤维以及孔、空腔等。如果外层是膜或板，则该铸塑树脂体系存在于外层和芯层之间，并部分或全部润湿外层。该铸塑树脂可用作各层之间的相互连结，这些层在铸塑树脂体系硬化前经热压。在纤维状外层情况下，该铸塑树脂体系同时用于固定纤维以及形成复合构件的表面。通过各层的相互粘结特别是赋予该复合构件以高强度和刚性。至少由芯层、两外层和铸塑树脂体系组成的复合体是现有技术已知的(如EP 1319503 A)，在本发明中下面也称为夹层结构。
铸塑树脂体系可以是单组分体系或多组分体系如双组分体系。其可以是发泡的或不发泡的。可能的铸塑树脂体系的实例是：聚氨酯(PUR)体系、聚酯树脂体系、环氧树脂体系、丙烯酸树脂体系。优选使用双组分PUR体系，特别优选如EP 1319503 A中第二页第26行到第三页第20行所述的双组分PUR体系。硬化的双组分PUR体系的面积重量优选为400-1200g/m2。
现有技术已知的夹层结构的面积重量优选为2100-3600g/m2。
按本发明，至少在复合构件的夹层结构的一个区域相互压制所述外层，并在压制区中用热塑性塑料包封该夹层结构。在本发明中该夹层结构的外层的相互压制是指，该夹层结构被压在一起，直到使外层几乎相互接触。处于外层之间的芯层此时被压紧到最小。
外层相互压制可使注塑法中的热塑性塑料在与夹层结构连结。在无相互压制的外层的现有技术已知的夹层结构中出现的问题是，在夹层结构中注塑热塑性塑料时，由于高的注塑压力使塑料不可控地伸展到芯层中，并由此使夹层结构变形或受损。因为按本发明相互压制该外层后该外层几乎相互邻近，所以在注塑时塑料熔体不可再在外层之间流入芯层。因此该相互压制阻止了塑料熔体在注塑时不可控地渗入芯层并由于处理热塑性塑料所需的高注入压力使芯层变形或受损。外层相互压制也阻止了复合构件的不可控的溢喷，因为该塑料熔体仅可在相互压制的外层区透入注塑工具的空腔。在其余未经压制的区域内，该复合构件邻近工具腔的内壁，由此该工具腔被密封，以防塑料熔体的不可控伸展。
外层例如可在该复合构件夹层结构的边缘区相互压制，并用热塑性塑料包封。这样，可对该夹层结构提供由热塑性塑料部分或连续包封的边缘。但复合构件的外层也可在制备时在任意的其它区相互压制，这取决于在复合构件的哪些区域要用热塑性塑料包封。如果该复合构件具有例如开口，则可压制例如该开口的边缘并用热塑性塑料包封。也可压制复合构件表面中的卷边和其它变形，并用塑料包封。
另一方面也可在复合构件的一个区域中使塑料熔体有针对性地进入芯层中，这可以产生下陷并由此产生夹层结构和热塑性塑料之间的形状合适的连接。这例如可如下实现，即离夹层结构或开口某一距离例如以圆形围绕开孔相互压制该复合构件外层。在注塑时塑料熔体经敞开的即未经压制的该开口的边缘进入芯层。但是，通过压制该塑料熔体可并非是不可控地扩展到芯层中，而仅例如围绕开口最多达经压制的范围。
用注塑法包封该夹层结构的热塑性塑料优选是基于聚酰胺(PA)、聚酯特别是聚对苯二甲酸乙二酯(PET)、聚对苯二甲酸丁二酯(PBT)、聚苯乙烯(PS)、丙烯腈-丁二烯-苯乙烯(ABS)、热塑性聚氨酯(TPU)、聚烯烃特别是聚丙烯(PP)、聚乙烯(PE)、聚碳酸酯(PC)、聚环氧丙烷(PPO)、聚砜(PSO)、聚苯硫(PPS)、聚酰亚胺(PI)、聚醚醚酮(PEEK)的非增强的、增强的和/或经填充的塑料或这些塑料的混合物。
由含铸塑树脂体系的芯层和外层组成的夹层结构以热塑性塑料的包封可提高该夹层结构的刚度和强度。此外，还可以各种方式将功能性部件如增强件、加固件或连接件注塑到夹层结构的任意位置，例如边缘处或表面上。由此可使由其它材料如金属制成的模制部件或构件较简单地与本发明的复合构件相连接。这样就可以较简单的方式使本发明的复合构件整合到由多个相同或不同模制部件或构件组成的整个体系中。也可以这种方式使本发明复合构件类型的多个模型部件相互连接。
本发明的另一目的在于提供一种制备本发明的复合构件的方法，该方法的特征在于下列步骤：
(i)将芯层和外层***压制工具中，将芯层置于外层之间
(ii)在至少一个外层上涂覆铸塑树脂体系，步骤(i)和(ii)可以任意顺序进行，
(iii)将芯层与外层压制成夹层结构以及在该夹层结构的至少一区域中相互压制外层，
(iv)使按步骤(iii)所压制的夹层结构脱模，
(v)将所压制的夹层结构插于注塑工具中，并将热塑性塑料注塑到相互压制的外层区域中的夹层结构上。
由现有技术已知的本发明的复合构件的夹层结构是借助于模压法制备的，即外层是通过压制，特别是整面的压制与芯层相连接(这里的步骤(iii))。在压制前，铸塑树脂体系以液态特别是整面地涂于至少一外层上(步骤(ii))。该铸塑树脂体系的涂覆可例如通过喷涂进行。该铸塑树脂体系的涂覆(步骤(ii))可在压制工具中在置入外层和芯层(步骤(i))后进行，或在压制工具外在置入外层和芯层前进行。在压制工具中芯层置于外压之间(步骤(i))，并接着进行压制(步骤(iii))。该方法的实施例如描述于EP 1319503 A中。
在铸塑树脂体系硬化前，按本发明该夹层结构的外层在所需区域如在边缘区经相互压制(步骤(iii))。压制芯层与外层使该层相互连接以及在所选区域相互压制外层可在压制工具中同时进行或相继进行。外层的相互压制有利地是在与相互压制芯层与外层以制成夹层结构本身的同一压制工具中进行。但原则上也同样可使该两分步骤在不同的压制工具中相继进行。经硬化、需要时冷却和脱模(步骤(iv))后，将经压制的夹层结构置于注塑工具中，并在该注塑工具中在相互压制的外层区域中用热塑性塑料包封该夹层结构(步骤(v))。
本发明的复合构件例如可在汽车制造中用于门衬里部件、车辆底板部件、仪器面板部件、仪器面板支架部件以及卧式车身部件，但也可用于家具或家用设备部件。注塑在经压制的夹层结构上的热塑性塑料可以是功能部件，如加强肋。
下面按附图详述本发明。
图1示出在压制的边缘区注塑热塑性塑料后的在注塑工具中的本发明复合构件片段的截面示意图
图2示出在压制的边缘区注塑热塑性塑料后的在注塑工具中的本发明复合构件片段的截面示意图，其中该塑料在未经压制区渗入芯层中
图3示出在该复合构件的压制开口区域中注塑热塑性塑料后的在注塑工具中的本发明复合构件片段的截面示意图
在图1中本发明的复合构件1位于注塑工具(未示出)的两半工具2、2’之间。该复合构件1由两外层3、3’和具有例如蜂窝状结构的芯层4构成。芯层4位于两外层3、3’之间。在图1中所示的复合构件1的实施方案中，外层3、3’在其边缘区5、5’处被相互压制，以使外层3、3’几乎相互紧邻。处于外层3、3’之间的芯层4在经压制的边缘区5、5’中几乎完全压紧。在经压制的边缘区5、5’中该复合构件1由热塑性塑料6所包封。该热塑性塑料6不是在相互压制的外层3、3’之间渗入到该复合构件1的芯层4中。
不同于图1所示的实施方案，在图2中示出的实施方案中两外层3、3’不直接在边缘区10、10’被相互压制，而是在离边缘10、10’某些距离的区域9、9’被相互压制。在未经压制的边缘区10、10’中向复合构件1注塑热塑性塑料6时，热塑性塑料6渗入芯层4，即渗入外层3、3’之间。该热塑性塑料6渗入芯层4直到经压制的区域9、9’。这样，该注塑的塑料6产生下陷。在经相互压制的外层3、3’的区域9、9’中，该塑料6不继续渗入芯层4中。该压制区9、9’阻止塑料熔体6继续、尤其是不可控地扩展到芯层4中。
图3示出复合构件1的另一实施方案，该构件位于注塑工具(未示出)的两半工具2、2’之间。外层3、3’具有相互叠置的开口7、7’。芯层在叠置的开口7、7’的区域中也具有开口11。外层3、3’在开口7、7’的周边8、8’经相互压制。相互叠置的开口7、7’、11用热塑性塑料6包封，以致该塑料6形成与复合构件1的形状合适的连接。
在另一未示出的实施方案中，例如还可为包封的热塑性塑料提供开口。
实施例：
夹层结构由厚6mm、面积重量约为1000g/m2的纸质峰窝结构体作为芯层和面积重量均约为400g/m2的两玻璃纤维层作为芯层的两面而构成。所述层用由多元醇和二异氰酸酯(Baypreg F，Bayer AG，德国)组成的面积重量约为400g/m2的聚氨酯铸塑树脂体系通过在压制工具中的压制相互连接。如此制成的夹层结构的面积重量为2630g/m2(密度为0.4g/cm3)。
在压制工具中相互压制各层时，同时即在一个加工步骤中在该聚氨酯铸塑树脂体系硬化前在其外边缘区中相互压制该夹层结构的外层。PUR树脂硬化后，将该模制件脱模，并将其置于注塑工具中。在该经压制的边缘区于注塑工具中对该夹层结构注塑聚酰胺6GF 30。注塑的塑料的厚度为6mm。复合构件的总厚度为6mm，密度约为0.7g/cm3，面积重量约为4400g/m2。该注塑的热塑性塑料不渗入外层中间的芯层中。

Claims (9)

1.一种基于夹层结构的复合构件，至少由下列组成：
(a)两个外层(3，3’)，其彼此独立地分别由至少一种由金属、塑料、玻璃、天然物质和/或碳制成的膜、板、纤维层和/或泡沫塑料组成，和
(b)置于外层(3，3’)之间的芯层(4)，其由含大量空腔的金属、塑料、天然物质和/或纸制成，
其中，铸塑树脂体系至少部分贯穿所述外层(3，3’)和芯层(4)，并通过压制使外层(3，3’)和芯层(4)相连接，其特征在于，所述外层(3，3’)在夹层结构的至少一个区域(5，5’，8，8’，9，9’)中相互压制，并且该夹层结构在压制区域(5，5’，8，8’，9，9’)中由热塑性塑料(6)所包封。
2.权利要求1的复合构件，其特征在于，所述芯层(b)具有波形的、角形的、蜂窝状或泡沫状结构。
3.权利要求1或2的复合构件，其特征在于，所述外层(a)是纤维层。
4.权利要求1-3之一的复合构件，其特征在于，所述铸塑树脂体系是双组分聚氨酯体系。
5.权利要求1-4之一的复合构件，其特征在于，在夹层结构的边缘区相互压制所述外层(a)，并用热塑性塑料包封经压制的边缘区。
6.权利要求1-5之一的复合构件，其特征在于，在夹层结构的开口、卷边或变形区相互压制所述外层(a)，并用热塑性塑料包封经压制的区。
7.权利要求1-6之一的复合构件，其特征在于，在所述经相互压制的外层(a)的区域附近的包封热塑性塑料至少部分充填所述芯层(b)的空腔，使得形成下陷。
8.权利要求1-7之一的复合构件，其特征在于，所述热塑性塑料是基于聚酰胺(PA)、聚酯特别是聚对苯二甲酸乙二酯(PET)、聚对苯二甲酸丁二酯(PBT)、聚苯乙烯(PS)、丙烯腈-丁二烯-苯乙烯(ABS)、热塑性聚氨酯(TPU)、聚烯烃特别是聚丙烯(PP)、聚乙烯(PE)、聚碳酸酯(PC)、聚环氧丙烷(PPO)、聚砜(PSO)、聚苯硫(PPS)、聚酰亚胺(PI)、聚醚醚酮(PEEK)的非增强的、增强的和/或经填充的塑料或这些塑料的混合物。
9.一种用于制备权利要求1-8之一的复合构件的方法，其特征在于下列步骤：
(i)将芯层和外层置于压制工具中，芯层位于外层之间，
(ii)在至少一个外层上涂覆铸塑树脂体系，步骤(i)和(ii)可以任意顺序进行，
(iii)将芯层与外层制压成夹层结构以及在该夹层结构的至少一区域中相互压制外层，
(iv)使按步骤(iii)所压制的夹层结构脱模，
(v)将所压制的夹层结构置于注塑工具中，并将热塑性塑料在相互压制的外层的区域中注塑在夹层结构上。
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ATE367263T1 (de) 2007-08-15
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US7419713B2 (en) 2008-09-02
US20050208263A1 (en) 2005-09-22

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