EP3131749A1 - Method for thermally insulating and sound-proofing components - Google Patents

Method for thermally insulating and sound-proofing components

Info

Publication number
EP3131749A1
EP3131749A1 EP15719632.0A EP15719632A EP3131749A1 EP 3131749 A1 EP3131749 A1 EP 3131749A1 EP 15719632 A EP15719632 A EP 15719632A EP 3131749 A1 EP3131749 A1 EP 3131749A1
Authority
EP
European Patent Office
Prior art keywords
thermoplastic polymer
components
polymer material
polypropylene
sound
Prior art date
Legal status (The legal status 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 status listed.)
Withdrawn
Application number
EP15719632.0A
Other languages
German (de)
French (fr)
Inventor
Jozef HUDINA
Josef Giesinger
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Henkel AG and Co KGaA
Original Assignee
Henkel AG and Co KGaA
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 Henkel AG and Co KGaA filed Critical Henkel AG and Co KGaA
Publication of EP3131749A1 publication Critical patent/EP3131749A1/en
Withdrawn legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D7/00—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
    • B05D7/50—Multilayers
    • B05D7/52—Two layers
    • B05D7/54—No clear coat specified
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/065—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
    • B32B27/20—Layered products comprising a layer of synthetic resin characterised by the use of special additives using fillers, pigments, thixotroping agents
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/306—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising vinyl acetate or vinyl alcohol (co)polymers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/34—Layered products comprising a layer of synthetic resin comprising polyamides
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/15—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer being manufactured and immediately laminated before reaching its stable state, e.g. in which a layer is extruded and laminated while in semi-molten state
    • B32B37/153—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer being manufactured and immediately laminated before reaching its stable state, e.g. in which a layer is extruded and laminated while in semi-molten state at least one layer is extruded and immediately laminated while in semi-molten state
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
    • 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
    • C08J9/36—After-treatment
    • C08J9/365—Coating
    • G—PHYSICS
    • G10—MUSICAL INSTRUMENTS; ACOUSTICS
    • G10K—SOUND-PRODUCING DEVICES; METHODS OR DEVICES FOR PROTECTING AGAINST, OR FOR DAMPING, NOISE OR OTHER ACOUSTIC WAVES IN GENERAL; ACOUSTICS NOT OTHERWISE PROVIDED FOR
    • G10K11/00—Methods or devices for transmitting, conducting or directing sound in general; Methods or devices for protecting against, or for damping, noise or other acoustic waves in general
    • G10K11/16—Methods or devices for protecting against, or for damping, noise or other acoustic waves in general
    • G10K11/162—Selection of materials
    • G10K11/168—Plural layers of different materials, e.g. sandwiches
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/10—Inorganic particles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/10—Inorganic particles
    • B32B2264/104—Oxysalt, e.g. carbonate, sulfate, phosphate or nitrate particles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B32B2266/0214—Materials belonging to B32B27/00
    • B32B2266/025—Polyolefin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/02—Cellular or porous
    • B32B2305/022—Foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/10—Properties of the layers or laminate having particular acoustical properties
    • B32B2307/102—Insulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2509/00—Household appliances
    • 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
    • C08J2323/00—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers
    • C08J2323/02—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers not modified by chemical after treatment
    • C08J2323/10—Homopolymers or copolymers of propene
    • C08J2323/12—Polypropene
    • 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
    • C08J2423/00—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers
    • C08J2423/02—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers not modified by chemical after treatment
    • C08J2423/10—Homopolymers or copolymers of propene
    • C08J2423/12—Polypropene

Definitions

  • the present invention relates to a method for thermal insulation and sound insulation and / or sound insulation of metallic components and / or plastic components.
  • the device container is in these cases usually made of thin stainless steel sheet with a typical thickness of about 0.4 mm.
  • the application of the heavy foil primarily serves to increase the mass of the container wall.
  • This approach is commonly referred to as "mass damping” and usually improves the acoustic properties of the device
  • the usually very thin-walled sheet would, for example, due to the sustained water jet pulses to the inside of the washing container, excited as a resonating body to vibrate and the device becomes a very disturbing noise source in the household.
  • the acoustic behavior of such devices is one of the main distinguishing features of individual products on the market in addition to the energy consumption and the quality of the rinsing or washing properties.
  • Bitumen-based materials as derivatives of heavy oil, are not among the preferred materials used in areas where food is stored and prepared, as is the case in a household kitchen. Nevertheless, the classic mass damping with asphalt heavy foils continues to be used due to lack of cost-effective alternatives. Another disadvantage of asphalt films is that such heavy films are very good heat conductors and thus lead to increased heat losses.
  • insulating layers have several advantages over the previously used asphalt films. First, they are, as already mentioned, toxicologically safe. In addition, they provide thermal insulation that minimizes energy loss in addition to a mass loss comparable to that achievable with asphalt heavy foil. Finally, they also offer an improved flame retardancy. In addition, the adhesion of the mass damping to the component can be improved by the construction according to the invention.
  • the invention relates to a method for sound insulation and / or sound insulation of metallic components and / or plastic components, wherein in the method in a first step, an insulating layer of a foamed thermoplastic polymer first material is applied to the components and then from a mass attenuation layer a second thermoplastic polymer material having a density of 1, 5 to 5 g / cm 3 is applied by direct extrusion at melting temperatures between 120 and 300 ° C on the insulating layer as a defined profile.
  • Metallic components are preferably thin-walled sheets of steel, aluminum and in particular stainless steel.
  • Plastic components can be made, for example, of thin-walled PVC, Polycarbonate, polypropylene, acrylonitrile-butadiene-styrene (ABS) polymers or glass fiber reinforced plastics (GRP) exist.
  • components to be coated are preferably components of so-called "white goods", ie household appliances or household appliances such as dishwashers, washing machines or bathtubs, shower trays, shower trays or sinks, but they can also be part of data processing equipment (computers), pump housings, compressors, be agricultural vehicles and equipment, medical equipment or housing chimneys of wind turbines.
  • the coated components are the housing or the rinsing body of a dishwashing or washing machine, in particular a dishwasher.
  • Such housing or flushing usually consist of stainless steel or in some cases also of polypropylene.
  • Thermoplastic polymer materials for the purposes of this invention are pure thermoplastic polymers to which additional fillers, optionally reinforcing agents and / or other additives have been added.
  • thermoplastic polymers to be used are vinyl polymers, in particular ethylene vinyl acetate (EVA), polyolefins, such as polypropylene and polyethylene, polyamides (PA), polyesters, polyacetals, polycarbonates, polyurethanes and ionomers.
  • EVA ethylene vinyl acetate
  • PA polyamides
  • polyesters polyacetals
  • polycarbonates polyurethanes and ionomers.
  • No thermoplastic polymer in the context of the present invention is bitumen.
  • the polymeric materials used herein are preferably free of bitumen.
  • the polymer preferably used in the described processes is polypropylene.
  • thermoplastic polymer material used as the insulating layer is a foamed material.
  • foam sheets may have a thickness in the range of 1 to 10 mm, preferably the thickness is in the range 2-5 mm.
  • foam sheets are applied to the components and preferably adhered thereto.
  • these foamed sheets are applied to the components by means of blow molding.
  • the insulating layer can be applied in such a way that all surfaces of a component, for example a rinsing container, are coated. Alternatively, the application can only take place on parts of the component. Likewise, the application of the mass damping layer can be made on all surfaces of a component, in particular on all surfaces that are already coated with the insulating layer. Alternatively, however, the ground damping layer can be applied only to parts of the surfaces of the component, in particular parts of the surfaces of the component which are coated with an insulating layer. In certain embodiments, the insulating layer may be at locations where additional material for mass damping, ie. the mass damping layer is applied, compressed and flattened, for example by means of pressing elements, such as pressure rollers.
  • a 4mm thick foam sheet may be compressed to 1mm at the locations where the bulk cushioning layer is applied, and then the 3mm thickness of the cushioning layer applied so that the component is completely coated with a 4mm thick coating.
  • the total layer thickness on the component is in various embodiments 3-6 mm, preferably about 4 mm.
  • the foam sheet may have the desired thickness of 3-6, preferably 4 mm, outside the area of the cover with the mass cushioning layer, and in areas where a mass cushioning layer is applied, the foam sheet is previously compressed to such a thickness that after application the mass damping layer, usually in a thickness of 2-5, preferably 3 mm, the desired total thickness of 3-6, preferably 4 mm is obtained, ie For example, compression can be made to a thickness of 1 mm.
  • the second thermoplastic polymer material used as the bulk cushioning layer may also contain one of the above-mentioned polymers. In order to achieve a high density of the thermoplastic polymer material, they should be highly filled, that is, have a filler content of at least 60 wt .-% based on the polymer material.
  • fillers serve inorganic salts or oxides, preferably those with a high density between 2.5 and about 12 g / cm 3 .
  • examples of such fillers are zinc oxide (ZnO), tin dioxide (SnO 2), titanium dioxide (titanium (IV) oxide, ⁇ 2), iron oxides - in particular iron (II) oxide (FeO), iron (II) oxide (iron sesquioxide Fe 2 O 3 ), Iron (II, II) oxide (ferroferrioxide Fe3U4, magnetite), barium sulfate (BaSC), lead sulfate (leadivitriol, PbSC), aluminum hydroxide, (for example in the form of hydrargillite, bayerite, nordstrandite) or aluminum metahydroxide ( eg in the form of diaspore or boehmite), hafnium boride, hafnium carbide, hafnium nitride, hafnium dioxide (HfC), tungsten oxides
  • rock or ore flours are dolomite, cassiterite (tinstone, SnC), bismuth (eulytine, pebble bismuth, Bi4 [Si04] 3), bismuth lignite (bismuthine, B12S3), ilmenite (titanium iron, FeTiCb) and granite rock flour.
  • a particularly preferred embodiment contains calcium carbonate as a filler, which can be used alone or in admixture with the other fillers.
  • the fillers used have a particle size range between 0.01 and 5000 ⁇ , preferably between 0.1 and 100 ⁇ , more preferably 0.5 and 20 ⁇ .
  • the density of the highly filled thermoplastic polymer materials used is generally in the range of 1.5 to 5 g / cm 3 , preferably in the range of 2.1 to 4.5 g / cm 3 .
  • temperatures in the range of 180 to 250 ° C are used in the extrusion of the second thermoplastic polymer material.
  • the thickness of the bulk cushioning layer of second thermoplastic polymer material is usually 1 to 10 mm, preferably about 2 to 5 mm.
  • the highly filled polymer material is preferably used in the form of granules.
  • the granules also called pellets
  • the grain size can be z. B. be determined by sieve analysis.
  • the grain has a spherical or lenticular shape, but it may also be elliptical or cylindrical.
  • the granules are to be surface free of adhesive or block free, so that sticking together to larger aggregates during storage and promotion of the granules is avoided.
  • the polymer materials used may additionally contain as such known auxiliaries.
  • the mass loss layer is applied by direct extrusion (DEX). This increases the degree of freedom of the device manufacturer, since no prefabricated heavy foils must be used. Instead, the position and the layer thickness of the coating can be chosen and set freely programmable.
  • DEX direct extrusion
  • Feeding the operational thermoplastic material to the extruder may be by gravity or pneumatic conveying systems. Under pneumatic conveying systems are understood in this context suction and / or blow conveyor.
  • thermoplastic material and / or other auxiliaries are preferably carried out by continuous gravimetric or volumetric dosing such that, depending on the application, a defined profile of constant or predetermined variable dimensions directly is applied from the extruder to the substrate to be coated, possibly preheated.
  • the individual components of the material can be supplied to the extruder in a volume-accurate manner.
  • the insulating layer and the grounding layer have the same polymer base, i.
  • both made of polypropylene materials both layers are welded and need not be glued.
  • methods may also be used in which the two layers are adhered.
  • a hot melt adhesive can be added to the second polymer material and / or the component can be coated with such a hot melt adhesive. Suitable hot melt adhesives are known in the art.
  • the insulating layer and / or the mass damping layer preferably at least the insulating layer, in particular only the insulating layer, hollow microspheres, in particular selected from glass, plastic or ceramic hollow microspheres, in particular ceramic hollow microspheres or glass microbubbles, preferably ceramic hollow microspheres and / or Glass microbubbles based on silicate / aluminate glasses or ceramics.
  • hollow microspheres in particular in the insulating layer, the thermal insulation and the material properties can be further improved.
  • Plastic hollow spheres for example made of polyethylene, polypropylene, polyurethane, polystyrene or a mixture thereof, can be used as organic hollow microspheres, for example.
  • the mineral hollow microspheres may contain, for example, clay, aluminum silicate, glass or mixtures thereof.
  • the organic or mineral hollow microspheres have a diameter of 1 to 1000 ⁇ , preferably from 5 to 200 ⁇ on.
  • the hollow microspheres may have a vacuum or partial vacuum in the interior or may be filled with air, inert gases, for example nitrogen, helium or argon, or reactive gases, for example oxygen.
  • Microbubble spheres are preferably used as hollow microspheres.
  • the hollow microspheres have a compressive strength of at least 50 bar, in particular of at least 100 bar, preferably 130 bar.
  • Hollow spheres preferably used according to the invention have Mohs hardness of at least 4, in particular at least 4.5, more preferably at least 5.
  • Micro hollow spheres preferred according to the invention have a shell diameter which is only about 5 to 15%, preferably only about 10%, of the total spheres (ie in other words about 85% to 95%, preferably about 90%, of the balls are formed by the cavity).
  • 3M-Scotchlite Glass Bubbles can be used as hollow glass microspheres or are commercially available from Omega Minerals Germany GmbH, Norderstedt, under the product designation "ISOSPHERES SG-300-B".
  • the preheating of the substrate prior to coating to a defined temperature can be carried out inductively by infrared radiation, laser radiation, hot air or in metallic substrates.
  • the inductive preheating can be carried out in particular dynamically, ie, a sensor determines the substrate temperature, this is then compared with a predetermined setpoint value to determine and adjust the necessary heating power of the induction heating.
  • corresponding preheating devices are mounted directly on the extruder head or immediately in front of it, so that the preheating takes place promptly for coating.
  • the procedure for generating the relative movement can be as follows:
  • manipulators for the purposes of this invention are devices that allow a physical interaction with the environment. In the specific case, this is the moving part of the structure that performs the mechanical work of the extruder head.
  • the manipulator used can be a robot with 5 or 6 axes of rotation or translation (rotational or translatory axes), whereby the combination of the individual movements is combined into one overall movement.
  • the robot can carry the extruder - including the preheater - and perform the relative movements. Similar robots are described for example in the documents US5358397, EP0787576 B1, DE10137214 A1.
  • the manipulator When both component and extruder die are moving, the manipulator is preferably located stationarily adjacent to a conveyor belt, the manipulator moving the extruder mounted thereon or the extruder die only along two mutually orthogonal axes.
  • the component to be coated is guided horizontally past the manipulator station on a conveyor device, this conveyor device optionally being provided with guide devices transverse to the transport direction, controlling the beginning and end of the extrusion of the coating material.
  • the component to be coated is passed by means of a suitable robot to the nozzle of the extruder.
  • the robot has up to 6 rotational or displacement axes.
  • the specific embodiment of both the conveyor and the coating station depends on the size and geometry of the components to be coated. If the component to be coated is, for example, a complete washing container of a washing machine, a dishwasher or a housing cockpit, the design of the conveying devices for feeding the components to the coating station must be adapted thereto. The manipulator or robot carrying out the coating must also be designed accordingly. Such devices are already known for example from the automotive industry.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Polymers & Plastics (AREA)
  • Health & Medical Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Medicinal Chemistry (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Physics & Mathematics (AREA)
  • Acoustics & Sound (AREA)
  • Multimedia (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Laminated Bodies (AREA)

Abstract

The invention relates to a method for sound-proofing and/or acoustically insulating metal components and/or plastics components. An insulating layer consisting of a foamed first thermoplastic polymer material is applied to the components and bonded thereto. A mass damping layer consisting of a second thermoplastic polymer material of a density of 1.5 to 5 g/cm3 is then applied to the insulating layer by direct extrusion at melt temperatures between 120 and 300° C as defined profile. The invention also concerns components produced by this method.

Description

Verfahren zur thermischen Isolierung und Schalldämmung von Bauteilen  Method for thermal insulation and sound insulation of components
Die vorliegende Erfindung betrifft ein Verfahren zum thermischen Isolieren und Schalldämmen und/oder Schallisolieren von metallischen Bauteilen und / oder Kunststoffbauteilen. The present invention relates to a method for thermal insulation and sound insulation and / or sound insulation of metallic components and / or plastic components.
Bei der Herstellung von modernen Geräten, Apparaten und Maschinen werden heutzutage fast ausschließlich sehr dünnwandige metallische Bleche oder Kunststoffbauteile eingesetzt. Mechanisch sich bewegende Teile, Wasch- und Spülvorgänge oder laufende Motoren versetzen diese dünnwandigen Bleche oder Kunststoffbauteile unvermeidbar in Schwingungen, die vielfach im Hörbereich des menschlichen Ohres sind. Diese Schwingungen werden in Form von Körperschall über die gesamte Maschine, den Apparat oder das Gerät fortgeleitet und können an entfernten Stellen in die Luft als störender Schall abgestrahlt werden. Zur Reduzierung der Schallabstrahlung und zur Körperschalldämpfung werden diese Bleche oder Kunststoffbauteile daher zum Beispiel im Automobilbau oder bei der Herstellung von Haushaltsgeräten mit schalldämpfenden Belägen, sogenannten Antidröhnbeschichtungen, versehen. In the manufacture of modern equipment, apparatus and machinery nowadays almost exclusively very thin-walled metallic sheets or plastic components are used. Mechanically moving parts, washing and rinsing processes or running motors inevitably cause these thin-walled sheets or plastic components to vibrate, which are often in the audible range of the human ear. These vibrations are transmitted in the form of structure-borne noise over the entire machine, the apparatus or the device and can be emitted at remote locations in the air as disturbing sound. To reduce the sound radiation and the structure-borne sound attenuation, these sheets or plastic components are therefore provided, for example, in the automotive industry or in the production of household appliances with sound-absorbing coverings, so-called anti-roughening coatings.
Nach herkömmlicher Verfahrensweise werden dabei Mischungen aus Füllstoffen mit hohem spezifischen Gewicht und Bitumen zu (Asphalt-)Folien extrudiert, aus denen dann die entsprechenden Formteile gestanzt oder geschnitten werden. Anschließend werden diese Folien auf die betreffenden Blechteile geklebt, wobei sie ggf. noch unter Erwärmen an die Form des Bleches angepasst werden müssen. In accordance with the conventional procedure, mixtures of fillers of high specific weight and bitumen are extruded into (asphalt) films, from which then the corresponding shaped parts are punched or cut. Subsequently, these films are glued to the sheet metal parts in question, they may need to be adjusted while heating to the shape of the sheet.
Es ist insbesondere für die so genannte „weiße Ware", d. h. Haushaltsgeräte oder Haushaltsmaschinen wie Geschirrspüler und Waschmaschinen, Stand der Technik diese zwecks Verbesserung ihres Geräuschverhaltens mit einer Asphalt-Schwerfolie akustisch zu dämpfen. Hierzu wird in der Regel eine vorkonfektionierte Asphalt-Schwerfolie auf die Außenflächen des Geräts aufgeschmolzen bzw. aufgeklebt. Der Gerätebehälter besteht in diesen Fällen meistens aus dünnem Edelstahlblech mit einer typischen Stärke von ca. 0,4 mm. It is particularly for the so-called "white goods", ie household appliances or household appliances such as dishwashers and washing machines, state of the art to attenuate them acoustically to improve their noise behavior with an asphalt heavy foil The device container is in these cases usually made of thin stainless steel sheet with a typical thickness of about 0.4 mm.
Das Aufbringen der Schwerfolie dient dabei vornehmlich der Erhöhung der Masse der Behälterwandung. Diese Vorgehensweise wird allgemein als „Massedämpfung" bezeichnet und verbessert in der Regel die akustischen Eigenschaften des Geräts. Ohne eine solche Maßnahme würde das zumeist sehr dünnwandige Blech, beim Geschirrspüler beispielsweise infolge der anhaltenden Wasserstrahlimpulse auf die Innenseite des Spülbehälters, als Resonanzkörper zum Schwingen angeregt und das Gerät zu einer stark störenden Geräuschquelle im Haushalt werden. Das akustische Verhalten derartiger Geräte ist allerdings neben dem Energieverbrauch und der Qualität der Spül- oder Wascheigenschaften eines der Hauptdifferenzierungsmerkmale einzelner Produkte auf dem Markt. The application of the heavy foil primarily serves to increase the mass of the container wall. This approach is commonly referred to as "mass damping" and usually improves the acoustic properties of the device Without such a measure, the usually very thin-walled sheet would, for example, due to the sustained water jet pulses to the inside of the washing container, excited as a resonating body to vibrate and the device becomes a very disturbing noise source in the household. The acoustic behavior of such devices, however, is one of the main distinguishing features of individual products on the market in addition to the energy consumption and the quality of the rinsing or washing properties.
Bitumen-basierte Materialien gehören als Derivate von Schweröl nicht zu den bevorzugten Stoffen, die in Bereichen eingesetzt werden, wo Lebensmittel aufbewahrt und zubereitet werden, so wie dies in einer Haushaltsküche der Fall ist. Dennoch findet die klassische Massedämpfung mit Asphalt-Schwerfolien infolge mangelnder kostengünstiger Alternativen weiterhin Verwendung. Ein weiterer Nachteil der Asphaltfolien liegt darin, dass solche Schwerfolien sehr gute Wärmeleiter sind und damit zu erhöhten Wärmeverlusten führen. Bitumen-based materials, as derivatives of heavy oil, are not among the preferred materials used in areas where food is stored and prepared, as is the case in a household kitchen. Nevertheless, the classic mass damping with asphalt heavy foils continues to be used due to lack of cost-effective alternatives. Another disadvantage of asphalt films is that such heavy films are very good heat conductors and thus lead to increased heat losses.
Aufgabe der vorliegenden Erfindung war es daher ein neues Verfahren bereitzustellen, dass es ermöglicht die akustische Massedämpfung, insbesondere von Haushaltsgeräten wie Geschirrspülmaschinen, ohne Verwendung von Bitumen vorzunehmen. It was therefore an object of the present invention to provide a new method that makes it possible to carry out the acoustic mass damping, in particular of household appliances such as dishwashers, without the use of bitumen.
Es wurde nun gefunden, dass sich diese Aufgabe durch ein Verfahren lösen lässt, in welchem anstelle einer Asphalt-Schwerfolie eine mehrschichtige Isolierung auf Basis Lebensmittelunbedenklicher Polypropylen-Materialien verwendet wird, wobei die mehrschichtige Isolierung eine direkt auf das Gerät aufgebrachte thermische Isolierschicht aus einer Polypropylen-Schaumfolie und eine darüber liegende Schicht aus hochgefülltem Polypropylen aufweist. It has now been found that this object can be achieved by a method in which, instead of an asphalt heavy foil, a multilayer insulation based on food-safe polypropylene materials is used, wherein the multilayer insulation has a thermal insulation layer of a polypropylene coating applied directly to the device. Foam sheet and has an overlying layer of highly filled polypropylene.
Diese Isolierschichten haben mehrere Vorteile gegenüber den bisher verwendeten Asphalt-Folien. Zum einen sind sie, wie bereits erwähnt, toxikologisch unbedenklicher. Darüber hinaus liefern sie zusätzlich zu einer Massedämpfung, die mit der, die durch Asphalt-Schwerfolien erreichbar ist, vergleichbar ist eine thermische Isolierung, die Energieverlust minimiert. Schließlich bieten sie auch noch einen verbesserten Flammschutz. Zudem kann durch den erfindungsgemäßen Aufbau die Haftung der Massedämpfung an das Bauteil verbessert werden. These insulating layers have several advantages over the previously used asphalt films. First, they are, as already mentioned, toxicologically safe. In addition, they provide thermal insulation that minimizes energy loss in addition to a mass loss comparable to that achievable with asphalt heavy foil. Finally, they also offer an improved flame retardancy. In addition, the adhesion of the mass damping to the component can be improved by the construction according to the invention.
In einem ersten Aspekt betrifft die Erfindung daher ein Verfahren zum Schalldämmen und/oder Schallisolieren von metallischen Bauteilen und/oder Kunststoffbauteilen, wobei in dem Verfahren in einem ersten Schritt eine Isolierschicht aus einem geschäumten ersten thermoplastischen Polymermaterial auf die Bauteile aufgebracht wird und dann eine Massedämpfungsschicht aus einem zweiten thermoplastischen Polymermaterial mit einer Dichte von 1 ,5 bis 5 g/cm3 durch direkte Extrusion bei Schmelztemperaturen zwischen 120 und 300° C auf die Isolierschicht als definiertes Profil aufgebracht wird. In a first aspect, therefore, the invention relates to a method for sound insulation and / or sound insulation of metallic components and / or plastic components, wherein in the method in a first step, an insulating layer of a foamed thermoplastic polymer first material is applied to the components and then from a mass attenuation layer a second thermoplastic polymer material having a density of 1, 5 to 5 g / cm 3 is applied by direct extrusion at melting temperatures between 120 and 300 ° C on the insulating layer as a defined profile.
Metallische Bauteile sind vorzugsweise dünnwandige Bleche aus Stahl, Aluminium und insbesondere Edelstahl. Kunststoffbauteile können beispielsweise aus dünnwandigen PVC-, Polycarbonat-, Polypropylen-, Acrylnitril-Butadien-Styrol- (ABS-) Polymeren oder Glasfaserverstärkten Kunstoffen (GFK) bestehen. Metallic components are preferably thin-walled sheets of steel, aluminum and in particular stainless steel. Plastic components can be made, for example, of thin-walled PVC, Polycarbonate, polypropylene, acrylonitrile-butadiene-styrene (ABS) polymers or glass fiber reinforced plastics (GRP) exist.
Diese zu beschichtenden Bauteile sind vorzugsweise Bestandteil von so genannter„weißer Ware", d. h. von Haushaltsgeräten oder Haushaltsmaschinen wie Geschirrspüler, Waschmaschinen, oder von Badewannen, Duschwannen, Duschtassen oder Spülbecken. Sie können aber auch Bestandteil von Datenverarbeitungsgeräten (Computern), Pumpengehäusen, Kompressoren, landwirtschaftlichen Fahrzeugen und Geräten, medizinischen Geräten oder Gehäusekanzeln von Windenergieanlagen sein. These components to be coated are preferably components of so-called "white goods", ie household appliances or household appliances such as dishwashers, washing machines or bathtubs, shower trays, shower trays or sinks, but they can also be part of data processing equipment (computers), pump housings, compressors, be agricultural vehicles and equipment, medical equipment or housing chimneys of wind turbines.
In verschiedenen Ausführungsformen handelt es sich bei den beschichteten Bauteilen um das Gehäuse oder den Spülkörper einer Geschirrspül- oder Waschmaschine, insbesondere einer Geschirrspülmaschine. Derartige Gehäuse oder Spülkörper bestehen üblicherweise aus Edelstahlblech oder in einigen Fällen auch aus Polypropylen. In various embodiments, the coated components are the housing or the rinsing body of a dishwashing or washing machine, in particular a dishwasher. Such housing or flushing usually consist of stainless steel or in some cases also of polypropylene.
Thermoplastische Polymermaterialien im Sinne dieser Erfindung sind sortenreine thermoplastische Polymere, denen zusätzlich Füllstoffe, ggf. Verstärkungsstoffe und/oder andere Additive beigemischt worden sind. Beispiele für zu verwendende thermoplastische Polymere sind Vinylpolymere, insbesondere Ethylenvinylacetat (EVA), Polyolefine, wie Polypropylen und Polyethylen, Polyamide (PA), Polyester, Polyacetale, Polycarbonate, Polyurethane und lonomere. Kein thermoplastisches Polymer im Sinne der vorliegenden Erfindung ist Bitumen. Die hierin verwendeten Polymermaterialien sind vorzugsweise frei von Bitumen. Das in den beschriebenen Verfahren vorzugsweise eingesetzte Polymer ist Polypropylen. Thermoplastic polymer materials for the purposes of this invention are pure thermoplastic polymers to which additional fillers, optionally reinforcing agents and / or other additives have been added. Examples of thermoplastic polymers to be used are vinyl polymers, in particular ethylene vinyl acetate (EVA), polyolefins, such as polypropylene and polyethylene, polyamides (PA), polyesters, polyacetals, polycarbonates, polyurethanes and ionomers. No thermoplastic polymer in the context of the present invention is bitumen. The polymeric materials used herein are preferably free of bitumen. The polymer preferably used in the described processes is polypropylene.
Das als Isolierschicht eingesetzte thermoplastische Polymermaterial ist ein geschäumtes Material. Besonders bevorzugt werden hierbei Schaumfolien aus thermoplastischen Polymeren, insbesondere Polypropylen. Derartige Schaumfolien können eine Dicke im Bereich von 1 bis 10 mm haben, vorzugsweise liegt die Dicke im Bereich 2-5 mm. The thermoplastic polymer material used as the insulating layer is a foamed material. Foams of thermoplastic polymers, in particular polypropylene, are particularly preferred. Such foam sheets may have a thickness in the range of 1 to 10 mm, preferably the thickness is in the range 2-5 mm.
Diese Schaumfolien werden auf die Bauteile aufgebracht und vorzugsweise damit verklebt. Besonders bevorzugt werden diese Schaumfolien mittels Blasformen auf die Bauteile aufgebracht. These foam sheets are applied to the components and preferably adhered thereto. With particular preference, these foamed sheets are applied to the components by means of blow molding.
Die Isolierschicht kann derart aufgebracht werden, dass alle Flächen eines Bauteils, beispielsweise eines Spülbehälters beschichtet sind. Alternativ kann die Auftragung nur auf Teile des Bauteils erfolgen. Ebenso kann die Auftragung der Massedämpfungsschicht auf alle Flächen eines Bauteils erfolgen, insbesondere auf alle Flächen, die bereits mit der Isolierschicht beschichtet sind. Alternativ kann aber auch die Massedämpfungsschicht nur auf Teile der Flächen des Bauteils, insbesondere Teile der Flächen des Bauteils die mit einer Isolierschicht beschichtet sind, aufgetragen werden. In bestimmten Ausführungsformen kann die Isolierschicht an Stellen wo zusätzliches Material zur Massedämpfung, d .h. die Massedämpfungsschicht, aufgetragen wird, komprimiert und flachgedrückt werden, beispielsweise mit Hilfe von Anpresselementen, wie Anpresswalzen. Dadurch lässt sich eine einheitliche Dicke der Beschichtung erzielen. Beispielsweise kann eine 4mm starke Schaumfolie an den Stellen, an denen die Massedämpfungsschicht aufgebracht wird auf 1 mm komprimiert und dann die Massedämpfungsschicht in einer Stärke von 3 mm aufgetragen werden, so dass das Bauteil komplett mit einer 4 mm starken Beschichtung versehen ist. The insulating layer can be applied in such a way that all surfaces of a component, for example a rinsing container, are coated. Alternatively, the application can only take place on parts of the component. Likewise, the application of the mass damping layer can be made on all surfaces of a component, in particular on all surfaces that are already coated with the insulating layer. Alternatively, however, the ground damping layer can be applied only to parts of the surfaces of the component, in particular parts of the surfaces of the component which are coated with an insulating layer. In certain embodiments, the insulating layer may be at locations where additional material for mass damping, ie. the mass damping layer is applied, compressed and flattened, for example by means of pressing elements, such as pressure rollers. This makes it possible to achieve a uniform thickness of the coating. For example, a 4mm thick foam sheet may be compressed to 1mm at the locations where the bulk cushioning layer is applied, and then the 3mm thickness of the cushioning layer applied so that the component is completely coated with a 4mm thick coating.
Die Gesamtschichtdicke auf dem Bauteil beträgt in verschiedenen Ausführungsformen 3-6 mm, vorzugsweise etwa 4 mm. Dabei kann die Schaumfolie außerhalb der Bereich der Abdeckung mit der Massedämpfungsschicht die gewünschte Dicke von 3-6, vorzugsweise 4 mm aufweisen, und in Bereichen, in denen eine Massedämpfungsschicht aufgetragen wird, wird die Schaumfolie vorher auf eine solche Dicke komprimiert, dass nach der Auftragung der Massedämpfungsschicht, üblicherweise in einer Dicke von 2-5, vorzugsweise 3 mm, die gewünschte Gesamtdicke von 3-6, vorzugsweise 4 mm erhalten wird , d.h. beispielsweise kann eine Komprimierung auf eine Dicke von 1 mm erfolgen. The total layer thickness on the component is in various embodiments 3-6 mm, preferably about 4 mm. The foam sheet may have the desired thickness of 3-6, preferably 4 mm, outside the area of the cover with the mass cushioning layer, and in areas where a mass cushioning layer is applied, the foam sheet is previously compressed to such a thickness that after application the mass damping layer, usually in a thickness of 2-5, preferably 3 mm, the desired total thickness of 3-6, preferably 4 mm is obtained, ie For example, compression can be made to a thickness of 1 mm.
Das zweite thermoplastische Polymermaterial, das als Massedämpfungsschicht eingesetzt wird, kann ebenfalls eines der oben genannten Polymere enthalten. Um eine hohe Dichte des thermoplastischen Polymermaterials zu erzielen, sollen diese hoch gefüllt sein, das heißt einen Füllstoffanteil von mindestens 60 Gew.-%bezogen auf das Polymermaterial haben. The second thermoplastic polymer material used as the bulk cushioning layer may also contain one of the above-mentioned polymers. In order to achieve a high density of the thermoplastic polymer material, they should be highly filled, that is, have a filler content of at least 60 wt .-% based on the polymer material.
Als Füllstoffe dienen anorganische Salze oder Oxide, vorzugsweise solche mit einer hohen Dichte zwischen 2,5 und etwa 12 g/cm3. Beispiele für derartige Füllstoffe sind Zinkoxid (ZnO), Zinndioxid (Sn02), Titandioxid (Titan(IV)-oxid, ΤΊΟ2), Eisenoxide - insbesondere Eisen(l l)-oxid (FeO), Eisen(ll l)-oxid (Eisensesquioxid Fe2Ü3), Eisen(ll ,l ll)-oxid (Ferroferrioxid Fe3Ü4, Magnetit), Bariumsulfat (BaSC ), Bleisulfat (Bleivitriol, PbSC ), Aluminiumhydroxid, (z. B. in Form von Hydrargillit, Bayerit, Nordstrandit) oder auch Aluminiummetahydroxid (z. B. in Form von Diaspor oder Böhmit), Hafniumborid, Hafniumcarbid, Hafniumnitrid, Hafniumdioxid (HfC ), Wolframoxide (z.B. Triwolframoxid (W3O), Wolframdioxid (Wolfram(IV)-oxid, WO2), Wolframtrioxid (Wolfram(VI)-oxid , WO3)), Rheniumdioxid (ReC ), Rheniumtrioxid (ReCb) und Rheniumheptoxid (Re2Ü7). As fillers serve inorganic salts or oxides, preferably those with a high density between 2.5 and about 12 g / cm 3 . Examples of such fillers are zinc oxide (ZnO), tin dioxide (SnO 2), titanium dioxide (titanium (IV) oxide, ΤΊΟ 2), iron oxides - in particular iron (II) oxide (FeO), iron (II) oxide (iron sesquioxide Fe 2 O 3 ), Iron (II, II) oxide (ferroferrioxide Fe3U4, magnetite), barium sulfate (BaSC), lead sulfate (leadivitriol, PbSC), aluminum hydroxide, (for example in the form of hydrargillite, bayerite, nordstrandite) or aluminum metahydroxide ( eg in the form of diaspore or boehmite), hafnium boride, hafnium carbide, hafnium nitride, hafnium dioxide (HfC), tungsten oxides (eg triwolframoxide (W3O), tungsten dioxide (tungsten (IV) oxide, WO2), tungsten trioxide (tungsten (VI) - oxide, WO3)), rhenium dioxide (ReC), rhenium trioxide (ReCb) and rhenium heptoxide (Re2Ü7).
Eine weitere Möglichkeit besteht darin, die entsprechenden Gesteins- oder Erzmehle als Füllstoff zu verwenden. Beispiele hierfür sind Dolomit, Kassiterit (Zinnstein, SnC ), Wismutblende (Eulytin, Kieselwismut, Bi4[Si04]3), Wismutglanz (Bismuthinit, Bismutin, B12S3), llmenit (Titaneisen, FeTiCb) sowie Granitgesteinsmehl. Another possibility is to use the corresponding rock or ore flours as filler. Examples of these are dolomite, cassiterite (tinstone, SnC), bismuth (eulytine, pebble bismuth, Bi4 [Si04] 3), bismuth lignite (bismuthine, B12S3), ilmenite (titanium iron, FeTiCb) and granite rock flour.
Ganz besonders bevorzugt ist die Verwendung von Schwerspat, Eisenoxiden, Aluminiumhydroxiden oder deren Mischung. Eine besonders bevorzugte Ausführungsform enthält Calciumcarbonat als Füllstoff, welches alleine oder in Mischung mit den anderen Füllstoffen eingesetzt werden kann. Very particular preference is given to the use of barite, iron oxides, aluminum hydroxides or mixtures thereof. A particularly preferred embodiment contains calcium carbonate as a filler, which can be used alone or in admixture with the other fillers.
Die einzusetzenden Füllstoffe haben einen Korngrößenbereich zwischen 0,01 und 5000μιη, vorzugsweise zwischen 0,1 und 100μιη, besonders bevorzugt 0,5 und 20μιη. The fillers used have a particle size range between 0.01 and 5000μιη, preferably between 0.1 and 100μιη, more preferably 0.5 and 20μιη.
Die Dichte der eingesetzten hoch gefüllten thermoplastischen Polymermaterialien liegt generell im Bereich von 1 ,5 bis 5 g/cm3, vorzugsweise im Bereich von 2, 1 bis 4,5 g/cm3. The density of the highly filled thermoplastic polymer materials used is generally in the range of 1.5 to 5 g / cm 3 , preferably in the range of 2.1 to 4.5 g / cm 3 .
In verschiedenen Ausführungsformen werden bei der Extrusion des zweiten thermoplastischen Polymermaterials Temperaturen im Bereich von 180 bis 250°C eingesetzt. In various embodiments, temperatures in the range of 180 to 250 ° C are used in the extrusion of the second thermoplastic polymer material.
Die Dicke der Massedämpfungsschicht aus zweitem thermoplastischem Polymermaterial beträgt üblicherweise 1 bis 10 mm, vorzugsweise etwa 2-5 mm. The thickness of the bulk cushioning layer of second thermoplastic polymer material is usually 1 to 10 mm, preferably about 2 to 5 mm.
Das hoch gefüllte Polymermaterial wird vorzugsweise in Form von Granulat eingesetzt. Das Granulat (auch Pellets genannt) kann einen Korndurchmesser von 0,5 mm bis 30 mm vorzugsweise von 2 bis 10 mm haben. Die Korngröße kann dabei z. B. durch Siebanalyse bestimmt werden. Vorzugsweise hat das Korn eine kugelartige oder linsenförmige Form, sie kann aber auch elliptisch oder zylinderförmig sein. Vorzugsweise sollen die Granulatteilchen oberflächlich kleb- bzw. blockfrei frei sein, damit ein Zusammenkleben zu größeren Aggregaten bei Lagerung und Förderung des Granulats vermieden wird. The highly filled polymer material is preferably used in the form of granules. The granules (also called pellets) may have a grain diameter of 0.5 mm to 30 mm, preferably from 2 to 10 mm. The grain size can be z. B. be determined by sieve analysis. Preferably, the grain has a spherical or lenticular shape, but it may also be elliptical or cylindrical. Preferably, the granules are to be surface free of adhesive or block free, so that sticking together to larger aggregates during storage and promotion of the granules is avoided.
Die verwendeten Polymermaterialien können zusätzlich als solche bekannte Hilfsstoffe enthalten. The polymer materials used may additionally contain as such known auxiliaries.
Die Massedämpfungsschicht wird mittels direkter Extrusion (DEX) aufgetragen. Das erhöht den Freiheitsgrad des Geräteherstellers, da keine vorkonfektionierten Schwerfolien mehr verwendet werden müssen. Stattdessen kann die Lage und die Schichtstärke der Beschichtung frei programmierbar gewählt und eingestellt werden. The mass loss layer is applied by direct extrusion (DEX). This increases the degree of freedom of the device manufacturer, since no prefabricated heavy foils must be used. Instead, the position and the layer thickness of the coating can be chosen and set freely programmable.
Das Zuführen des einsatzfähigen thermoplastischen Materials zum Extruder kann durch Schwerkraft oder pneumatische Fördersysteme erfolgen. Unter pneumatischen Fördersystemen werden in diesem Zusammenhang Saug- und / oder Blasförderer verstanden. Feeding the operational thermoplastic material to the extruder may be by gravity or pneumatic conveying systems. Under pneumatic conveying systems are understood in this context suction and / or blow conveyor.
Das Zuführen des thermoplastischen Materials und / oder weitere Hilfsstoffe, erfolgt dabei vorzugsweise durch kontinuierliche gravimetrische oder volumetrische Dosierung derart, dass je nach Applikation ein definiertes Profil konstanter oder vorgegeben variabler Abmessungen direkt aus dem Extruder auf das zu beschichtende, ggf. vorgeheizte, Substrat aufgebracht wird. Alternativ können die Einzelkomponenten des Materials mengengenau dem Extruder zugeführt werden. The feeding of the thermoplastic material and / or other auxiliaries, is preferably carried out by continuous gravimetric or volumetric dosing such that, depending on the application, a defined profile of constant or predetermined variable dimensions directly is applied from the extruder to the substrate to be coated, possibly preheated. Alternatively, the individual components of the material can be supplied to the extruder in a volume-accurate manner.
Es ist bevorzugt, dass die Isolierschicht und die Massedämpfungsschicht die gleiche Polymerbasis aufweisen, d.h. beispielsweise beide aus Polypropylen-Materialien bestehen. Dadurch werden bei der direkten Extrusion des zweiten Polymermaterials beide Schichten verschweißt und müssen nicht verklebt werden. Obwohl ein derartiges Verschweißen bevorzugt ist, können in alternativen Ausführungsformen auch Verfahren angewandt werden, in denen die beiden Schichten verklebt werden. Dazu kann dem zweiten Polymermaterial ein Schmelzklebstoff beigemischt werden und/oder das Bauteil mit einem solchen Schmelzklebstoff beschichtet werden. Geeignete Schmelzklebstoffe sind im Stand der Technik bekannt. It is preferred that the insulating layer and the grounding layer have the same polymer base, i. For example, both made of polypropylene materials. As a result, in the direct extrusion of the second polymer material, both layers are welded and need not be glued. Although such welding is preferred, in alternative embodiments, methods may also be used in which the two layers are adhered. For this purpose, a hot melt adhesive can be added to the second polymer material and / or the component can be coated with such a hot melt adhesive. Suitable hot melt adhesives are known in the art.
Gemäß einer besonders bevorzugten Ausführungsform enthalten die Isolierschicht und/oder die Massedämpfungsschicht, bevorzugt zumindest die Isolierschicht, insbesondere nur die Isolierschicht, Mikrohohlkugeln, insbesondere ausgewählt aus Glas-, Kunststoff- oder keramischen Mikrohohlkugeln, insbesondere keramischen Mikrohohlkugeln oder Glasmikrohohlkugeln, vorzugsweise keramischen Mikrohohlkugeln und/oder Glasmikrohohlkugeln auf Basis von Silikat/Aluminat-Gläsern bzw. -Keramiken. Durch die Verwendung von Mikrohohlkugeln, insbesondere in der Isolierschicht, kann die thermische Isolierung und die Materialeigenschaften weiter verbessert werden. Als organische Mikrohohlkugeln können beispielsweise Kunststoffhohlkugeln, z.B. aus Polyethylen, Polypropylen, Polyurethan, Polystyrol oder einen Gemisch daraus, eingesetzt werden. Die mineralischen Mikrohohlkugeln können beispielsweise Ton, Aluminiumsilikat, Glas oder Gemische daraus enthalten. Insbesondere weisen die organischen oder mineralischen Mikrohohlkugeln einen Durchmesser von 1 bis 1000 μιη, bevorzugt von 5 bis 200 μιη auf. Die Mikrohohlkugeln können im Inneren ein Vakuum oder Teilvakuum auf- weisen oder mit Luft, Inertgasen, beispielsweise Stickstoff, Helium oder Argon, oder Reaktivgasen, beispielsweise Sauerstoff, gefüllt sein. Bevorzugt werden als Mikrohohlkugeln Mikroglashohlkugeln verwendet. In einer besonders bevorzugten Ausführungsform weisen die Mikrohohlkugeln eine Druckfestigkeit von mindestens 50 bar, insbesondere von mindestens 100 bar, bevorzugt 130 bar auf. Erfindungsgemäß bevorzugt verwendete Mikrohohlkugeln besitzen Härten nach Mohs von mindestens 4, insbesondere mindestens 4,5, besonders bevorzugt mindestens 5. Erfindungsgemäß bevorzugte Mikrohohlkugeln haben einen Hüllendurchmesser, welcher nur ca. 5 bis 15 %, vorzugsweise nur etwa 10 %, der Gesamtkugeln ausmacht (d. h. mit anderen Worten ca. 85 % bis 95 %, vorzugsweise etwa 90 %, der Kugeln werden vom Hohlraum gebildet). Beispielsweise können als Mikrohohlglaskugeln 3M - Scotch- lite Glass Bubbles verwendet werden oder sind kommerziell erhältlich von der Omega Minerals Germany GmbH, Norderstedt, unter der Produktbezeichnung "ISOSPHERES SG-300-B". Die Vorheizung des Substrates vor der Beschichtung auf eine definierte Temperatur kann dabei durch Infrarotstrahlung, Laserstrahlung, Heißluftzufuhr oder bei metallischen Substraten auch induktiv erfolgen. Die induktive Vorheizung kann dabei insbesondere dynamisch erfolgen, d. h. ein Sensor ermittelt die Substrattemperatur, diese wird dann mit einem vorgegebenen Sollwert verglichen, um daraus die notwendige Heizleistung der Induktionsheizung zu ermitteln und einzustellen. Vorzugsweise sind entsprechende Vorheizvorrichtungen direkt am Extruderkopf oder unmittelbar davor angebracht, so dass die Vorheizung zeitnah zur Beschichtung erfolgt. According to a particularly preferred embodiment, the insulating layer and / or the mass damping layer, preferably at least the insulating layer, in particular only the insulating layer, hollow microspheres, in particular selected from glass, plastic or ceramic hollow microspheres, in particular ceramic hollow microspheres or glass microbubbles, preferably ceramic hollow microspheres and / or Glass microbubbles based on silicate / aluminate glasses or ceramics. By using hollow microspheres, in particular in the insulating layer, the thermal insulation and the material properties can be further improved. Plastic hollow spheres, for example made of polyethylene, polypropylene, polyurethane, polystyrene or a mixture thereof, can be used as organic hollow microspheres, for example. The mineral hollow microspheres may contain, for example, clay, aluminum silicate, glass or mixtures thereof. In particular, the organic or mineral hollow microspheres have a diameter of 1 to 1000 μιη, preferably from 5 to 200 μιη on. The hollow microspheres may have a vacuum or partial vacuum in the interior or may be filled with air, inert gases, for example nitrogen, helium or argon, or reactive gases, for example oxygen. Microbubble spheres are preferably used as hollow microspheres. In a particularly preferred embodiment, the hollow microspheres have a compressive strength of at least 50 bar, in particular of at least 100 bar, preferably 130 bar. Hollow spheres preferably used according to the invention have Mohs hardness of at least 4, in particular at least 4.5, more preferably at least 5. Micro hollow spheres preferred according to the invention have a shell diameter which is only about 5 to 15%, preferably only about 10%, of the total spheres (ie in other words about 85% to 95%, preferably about 90%, of the balls are formed by the cavity). For example, 3M-Scotchlite Glass Bubbles can be used as hollow glass microspheres or are commercially available from Omega Minerals Germany GmbH, Norderstedt, under the product designation "ISOSPHERES SG-300-B". The preheating of the substrate prior to coating to a defined temperature can be carried out inductively by infrared radiation, laser radiation, hot air or in metallic substrates. The inductive preheating can be carried out in particular dynamically, ie, a sensor determines the substrate temperature, this is then compared with a predetermined setpoint value to determine and adjust the necessary heating power of the induction heating. Preferably, corresponding preheating devices are mounted directly on the extruder head or immediately in front of it, so that the preheating takes place promptly for coating.
Zur Beschichtung des Substrates müssen das zu beschichtende Bauteil und der Extruderkopf mit daran anmontierter Düse eine Relativbewegung zueinander ausführen. Dabei kann zur Erzeugung der Relativbewegung wie folgt vorgegangen werden: In order to coat the substrate, the component to be coated and the extruder head with nozzle mounted thereon must execute a relative movement relative to one another. In this case, the procedure for generating the relative movement can be as follows:
• das Bauteil steht still und die Düse bewegt sich, oder  • the component stops and the nozzle moves, or
• sowohl Bauteil, als auch Düse bewegen sich, oder  • both component and nozzle are moving, or
• die Düse ist ortsfest und das Bauteil bewegt sich.  • The nozzle is stationary and the component moves.
Die Erzeugung der Relativbewegung erfolgt vorzugsweise durch Manipulatoren. Manipulatoren im Sinne dieser Erfindung sind Geräte, die eine physikalische Interaktion mit der Umgebung ermöglicht. Im konkreten Fall ist dies der bewegliche Teil des Aufbaus, der die mechanische Arbeit des Extruderkopfes durchführt. The generation of the relative movement is preferably carried out by manipulators. Manipulators for the purposes of this invention are devices that allow a physical interaction with the environment. In the specific case, this is the moving part of the structure that performs the mechanical work of the extruder head.
Für die Fälle der sich bewegenden Düse kann der eingesetzte Manipulator ein Roboter mit 5 oder 6 Dreh- bzw. Verschiebeachsen (rotatorische- bzw. translatorische Achsen) sein, wodurch die Kombination der einzelnen Bewegungen zu einer Gesamtbewegung zusammengefasst wird. For the cases of the moving nozzle, the manipulator used can be a robot with 5 or 6 axes of rotation or translation (rotational or translatory axes), whereby the combination of the individual movements is combined into one overall movement.
Dabei kann der Roboter den Extruder - samt Vorheizvorrichtung - tragen und die Relativbewegungen ausführen. Ähnliche Roboter sind beispielsweise in den Schriften US5358397, EP0787576 B1 , DE10137214 A1 beschrieben. The robot can carry the extruder - including the preheater - and perform the relative movements. Similar robots are described for example in the documents US5358397, EP0787576 B1, DE10137214 A1.
Wenn sich sowohl Bauteil als auch Extruderdüse bewegen, ist der Manipulator vorzugsweise ortsfest neben einem Förderband angeordnet, wobei der Manipulator den darauf montierten Extruder oder die Extruderdüse nur entlang zweier zueinander orthogonaler Achsen bewegt. Das zu beschichtende Bauteil wird auf einer Fördervorrichtung horizontal an der Manipulatorstation vorbeigeführt, wobei diese Fördervorrichtung gegebenenfalls mit Führungsvorrichtungen quer zur Transportrichtung versehen ist, die Beginn und Ende der Extrusion des Beschichtungsmaterials steuern. When both component and extruder die are moving, the manipulator is preferably located stationarily adjacent to a conveyor belt, the manipulator moving the extruder mounted thereon or the extruder die only along two mutually orthogonal axes. The component to be coated is guided horizontally past the manipulator station on a conveyor device, this conveyor device optionally being provided with guide devices transverse to the transport direction, controlling the beginning and end of the extrusion of the coating material.
Wenn die Düse ortsfest angeordnet ist, wird das zu beschichtende Bauteil mit Hilfe eines geeigneten Roboters an der Düse des Extruders vorbeigeführt. Der Roboter hat dabei je nach Geometrie und Größe des zu beschichtenden Bauteils 2 bis zu 6 Dreh- bzw. Verschiebeachsen. Die konkrete Ausgestaltung sowohl der Fördervorrichtung als auch der Beschichtungsstation richtet sich nach Größe und Geometrie der zu beschichtenden Bauteile. Wenn das zu beschichtende Bauteil beispielsweise ein kompletter Spülbehälter einer Waschmaschine, eines Geschirrspülers oder einer Gehäusekanzel ist, muss die Ausgestaltung der Fördereinrichtungen zur Zuführung der Bauteile zur Beschichtungsstation darauf abgestimmt werden. Auch der die Beschichtung ausführende Manipulator oder Roboter muss entsprechend ausgestaltet werden. Derartige Vorrichtungen sind bereits beispielsweise aus der Fahrzeugindustrie bekannt. If the nozzle is arranged stationary, the component to be coated is passed by means of a suitable robot to the nozzle of the extruder. Depending on the geometry and size of the component 2 to be coated, the robot has up to 6 rotational or displacement axes. The specific embodiment of both the conveyor and the coating station depends on the size and geometry of the components to be coated. If the component to be coated is, for example, a complete washing container of a washing machine, a dishwasher or a housing cockpit, the design of the conveying devices for feeding the components to the coating station must be adapted thereto. The manipulator or robot carrying out the coating must also be designed accordingly. Such devices are already known for example from the automotive industry.

Claims

Patentansprüche claims
1. Verfahren zum Schalldämmen und/oder Schallisolieren von metallischen Bauteilen und/oder Kunststoffbauteilen, dadurch gekennzeichnet, dass eine Isolierschicht aus einem geschäumten ersten thermoplastischen Polymermaterial auf die Bauteile aufgebracht wird und dann eine Massedämpfungsschicht aus einem zweiten thermoplastischen Polymermaterial mit einer Dichte von 1 ,5 bis 5 g/cm3 durch direkte Extrusion bei Schmelztemperaturen zwischen 120 und 300° C auf die Isolierschicht als definiertes Profil aufgebracht wird. 1. A method for sound insulation and / or sound insulation of metallic components and / or plastic components, characterized in that an insulating layer of a foamed thermoplastic polymer first material is applied to the components and then a mass attenuation layer of a second thermoplastic polymer material having a density of 1, 5th to 5 g / cm 3 by direct extrusion at melting temperatures between 120 and 300 ° C is applied to the insulating layer as a defined profile.
2. Verfahren nach Anspruch 1 , dadurch gekennzeichnet, dass die Bauteile für Haushaltsgeräte oder Haushaltsmaschinen verwendet werden oder Bestandteil von Haushaltsgeräten oder Haushaltsmaschinen sind. 2. The method according to claim 1, characterized in that the components are used for household appliances or household machines or are part of household appliances or household appliances.
3. Verfahren nach Anspruch 1 , dadurch gekennzeichnet, es sich bei den Bauteilen um Spülbecken, Badewannen, Duschwannen oder Duschtassen handelt. 3. The method according to claim 1, characterized in that it is the components to sinks, bathtubs, shower trays or shower trays.
4. Verfahren nach mindestens einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, das die zu beschichtenden Substrate aus Edelstahl oder PVC-, Polycarbonat-, Polypropylen-, Acrylnitril-Butadien-Styrol- (ABS-) Polymeren oder Glasfaser-verstärkten Kunstoffen (GFK) bestehen. 4. The method according to at least one of the preceding claims, characterized in that the substrates to be coated made of stainless steel or PVC, polycarbonate, polypropylene, acrylonitrile-butadiene-styrene (ABS) polymers or glass fiber reinforced plastics (GRP) exist ,
5. Verfahren nach mindestens einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, das das erste thermoplastische Polymermaterial eine Schaumfolie, insbesondere eine Polypropylen-Schaumfolie ist. 5. The method according to at least one of the preceding claims, characterized in that the first thermoplastic polymer material is a foam sheet, in particular a polypropylene foam sheet.
6. Verfahren nach mindestens einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, das das erste thermoplastische Polymermaterial mittels Blasformen auf die Bauteile aufgebracht und vorzugsweise verklebt wird. 6. The method according to at least one of the preceding claims, characterized in that the first thermoplastic polymer material is applied by means of blow molding on the components and preferably glued.
7. Verfahren nach mindestens einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, dass das zweite thermoplastische Polymermaterial ein mit anorganischen Salzen hochgefülltes Polypropylen (PP), Ethylenvinylacetat (EVA) oder Polyamid, insbesondere ein mit anorganischen Salzen hochgefülltes Polypropylen (PP), ist. 7. The method according to at least one of the preceding claims, characterized in that the second thermoplastic polymer material is highly filled with inorganic salts of polypropylene (PP), ethylene vinyl acetate (EVA) or polyamide, in particular a highly filled with inorganic salts of polypropylene (PP).
8. Verfahren nach Anspruch 7, dadurch gekennzeichnet, dass 8. The method according to claim 7, characterized in that
die anorganischen Salze ausgewählt werden aus Bariumsulfat, Aluminiumhydroxid und / oder Eisenoxiden und/oder das zweite thermoplastische Polymermaterial Dichten zwischen 2, 1 und 4,5 g/cm3 aufweist und/oder the inorganic salts are selected from barium sulfate, aluminum hydroxide and / or iron oxides and / or the second thermoplastic polymer material has densities between 2, 1 and 4.5 g / cm 3 and / or
das zweite thermoplastische Polymermaterial bei Temperaturen zwischen 180 und 250° C aufgebracht werden.  the second thermoplastic polymer material may be applied at temperatures between 180 and 250 ° C.
9. Verfahren nach mindestens einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, dass das zweite thermoplastische Polymermaterial vor der Erwärmung in Granulatform vorliegt. 9. The method according to at least one of the preceding claims, characterized in that the second thermoplastic polymer material is in granular form prior to heating.
10. Verfahren nach mindestens einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, dass die Isolierschicht und/oder die Massedämpfungsschicht Mikrohohlkugeln enthält. 10. The method according to at least one of the preceding claims, characterized in that the insulating layer and / or the mass attenuation layer contains hollow microspheres.
1 1. Schallgedämmtes und/oder schallisoliertes metallisches oder Kunststoffbauteil erhältlich gemäß einem Verfahren nach mindestens einem der Ansprüche 1-10. 1 1. Sound-insulated and / or sound-insulated metallic or plastic component obtainable according to a method according to any one of claims 1-10.
EP15719632.0A 2014-04-15 2015-04-14 Method for thermally insulating and sound-proofing components Withdrawn EP3131749A1 (en)

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DE102014207161.5A DE102014207161A1 (en) 2014-04-15 2014-04-15 Method for thermal insulation and sound insulation of components
PCT/EP2015/058007 WO2015158680A1 (en) 2014-04-15 2015-04-14 Method for thermally insulating and sound-proofing components

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