JP2013538137A - 発泡性媒体及び表層を用いるインモールド発泡法、並びに当該方法により得られるプラスチック成形体 - Google Patents
発泡性媒体及び表層を用いるインモールド発泡法、並びに当該方法により得られるプラスチック成形体 Download PDFInfo
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Classifications
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Abstract
Description
複合材用の変形法は、公知である。そこでブロー成形法(Schlausblasverfahren)の場合、チューブ(例えばシリコーンチューブ製のもの)を用い、複合材製の粗加工品、例えばガラス繊維又は炭素繊維で強化されたプラスチック製の粗加工品を型にブローしてその型に合わせ、熱により硬化させる。
・事前に作製した負荷導入要素を、中空構造を有する繊維半製品上に配置する工程、
・前記繊維半製品中に、弾性中空体を導入する工程、
・配置構成全体を、温度調整可能な型の中に置く工程、
・前記型の中で、前記負荷導入要素を位置決めする工程、
・前記半製品が、前記型の輪郭と前記負荷導入要素の輪郭に押しつけられるよう、前記弾性中空体を充填する工程、
・マトリックス複合材を満たし、熱により硬化させる工程、
・硬化後に、シャフトを取り出す工程。
・「通常の」PUR発泡の場合、発泡させて部材にする(発泡成形と同様)、
・PURを用いて「犠牲コア」を製造し、これはその後、表層で覆うことができる。この場合、このプロセスには複数の工程が含まれる。
・PURの場合には、液相から発泡させる。
従って本発明の課題は、以下の通りである:
・その場で(in−situ)発泡させるための方法の開発、
・発泡体で満たされた三次元形状の部材(プラスチックフォーム複合成形体)を製造するための、容易な一工程法の開発、
・発泡体で満たされた三次元形状の部材(プラスチックフォーム複合成形体)であって、1つ及び/又は複数の表層で取り囲まれたものを製造するための、容易な一工程法の開発、ここで前記表層は、相互に結合されていてよく、
・プラスチックフォーム複合成形体から、軽構造クラッシュ要素を製造すること、
・発泡コアと、1つ又は複数の表層とを有する成形部材及び異形材構造を製造すること、
・平面状プラスチックフォーム複合成形体の製造、
・力が導入される(挿入部)、又は結合性、又は補強性の構造を有する統合部材の製造、
・発泡シートのその場での(in−situ)製造、
・センサー、
・密度が可変/調整可能な部材の製造、
・アンテナ(スペーサー)、
・圧力安定性、座屈安定性、くぼみ安定性を向上させるための要素の製造、
・充分に均質な発泡構造の作製、
・異方性の機械的特性を有する部材の製造、
・プラスチックフォーム複合成形体による、縦方向及び横方向の部材(例えば自動車におけるAピラー、Bピラー、及びCピラー)の強化。
本発明の課題は、プラスチックフォーム複合成形体によって、またその製造方法によって、以下のように解決される:
固体の発泡可能なプラスチック(例えばポリ(メタ)アクリルイミド(PMI)、ポリビニルクロリド(PVC)、ポリウレタン(PUR)、ポリ(メタ)アクリレート(PMMA))を用いることにより、実質的に均質なプラスチックフォーム複合成形体が製造でき、当該成形体は発泡プロセスの間、1つの表層と、又は同種若しくは異なる複数の表層と、機械的に安定に結合する。
プラスチックフォーム複合成形体の表層は例えば、以下のものからなり得る:
・強化物質を有する、又は有さない熱可塑性材料、例えば様々なポリアミド類(PA、PA66、PA12)、ポリプロピレン(PP)、ポリブチレンテレフタレート(PBT)、ポリエーテルエーテルケトン(PEEK)、これらは、例えばガラス繊維、アラミド繊維、ポリマー繊維、天然繊維、又は炭素繊維によって強化されていてもよく、強化されたものの例はPA6GFであり、
・熱可塑性の繊維強化物質又は有機プレート、例えば連続繊維で強化されたPA6、
・補強物質を有する、又は有さない熱硬化性材料、例えばプリプレグ、
・補強物質のみ、例えばガラス製、炭素製、アラミド製、ポリマー製の繊維、例えばバサルト繊維、ホウ素繊維、セラミック繊維、金属繊維、ポリエステル繊維、ナイロン繊維、ポリエチレン繊維、プレキシガラス繊維、天然繊維、例えば木質繊維、亜麻繊維、麻繊維、サイザル麻繊維、
・金属、例えばアルミニウム、鋼、高強度鋼、
・エラストマー、例えばゴム、PUR、繊維強化ゴム、又は繊維強化PUR、
・ゲルコート、及び
・上記材料の1種又は複数種の組み合わせ、例えばガラス繊維不織布と、炭素繊維不織布との組み合わせを有する多層構造体(積層体)。
・ガラス繊維、例えば短繊維ガラス、長繊維ガラス、連続繊維、繊維不織布、繊維織布、ニット、フリース又はマットの形状で、
・炭素繊維、例えば短繊維ガラス、長繊維ガラス、連続繊維、繊維不織布、繊維織布、ニット、フリース、又はマットの形状で、
・アラミド繊維、例えば短繊維ガラス、長繊維ガラス、連続繊維、繊維不織布、繊維織布、ニット、フリース、又はマットの形状で、
・天然繊維、例えば木質繊維、亜麻繊維、麻繊維、サイザル麻繊維、
・プラスチック繊維、例えばポリエステル繊維、ナイロン繊維、ポリエチレン繊維、プレキシガラス繊維、
・ガラスビーズ、例えばガラスビーズで強化されたポリアミド(例えば、PA 6 GK30)。
本発明の方法に特に関連するコア層は、ポリ(メタ)アクリルイミド発泡体を有する。
重合開始剤としては、(メタ)アクリレートの重合にそれ自体通常のものを使用し、それは例えばアゾ化合物(例えばアゾジイソブチロニトリル)、並びに過酸化物(例えばジベンゾイルペルオキシド若しくはジラウロイルペルオキシド)、又は他の過酸化物化合物(例えばt−ブチルペルオクタノエート若しくはペルケタール)、また例えば任意でレドックス開始剤である(これについては例えば、H. Rauch-Puntigam, Th. Voelker, Acryl- und Methacrylverbindungen, Springer, Heidelberg, 1967、又はKirk-Othmer, Encyclopedia of Chemical Technology, Vol. 1 , p 286 ff, John Wiley & Sons, New York, 1978を参照)。重合開始剤は好ましくは、出発物質に対して0.01〜0.3質量%の量で使用する。
コポリマーの分子量調節は、モノマー混合物の重合によって、分子量調節剤の存在下で行い、前記調節剤は例えば、特にそのために公知のメルカプタン、例えばn−ブチルメルカプタン、n−ドデシルメルカプタン、2−メルカプトエタノール、若しくは2−エチルヘキシルチオグリコレート、又はキノン、又はテルペンであり、ここでこれらの調節剤は一般的に、それぞれモノマー混合物に対して0.01〜5質量%の量、好ましくは0.1〜2質量%の量、特に好ましくは0.2〜1質量%の量で使用する(例えばH. Rauch-Puntigam, Th. Voelker, "Acryl- und Methacrylverbindungen", Springer, Heidelberg, 1967; Houben-Weyl, Methoden der organischen Chemie, Bd. XIV/1 , p66, Georg Thieme, Heidelberg, 1961、又はKirk-Othmer, Encyclopedia of Chemical Technology, Vol. 1 , p296ff, J. Wiley, New York, 1978参照)。
1.以下の(a)〜(f)から成る組成物のラジカル共重合による、コポリマープレートの製造;
(a)メタクリロニトリル20〜60質量%、メタクリル酸80〜40質量%、及び任意で、メタクリル酸とメタクリロニトリルの合計に対して最大20質量%の別の単官能性ビニル不飽和モノマーから成る混合物、
(b)ホルムアミド若しくはモノメチルホルムアミドと、分子中に3〜8個の炭素原子を有する一価の脂肪族アルコールとの発泡剤混合物0.5〜15質量%、
(c)以下の(c1)及び(c2)から成る架橋剤系
(c1)分子中に二重結合を少なくとも2個有する、ラジカル重合可能なビニル不飽和化合物0.005〜5質量%、及び
(c2)モノマー混合物中に溶解された酸化マグネシウム又は酸化亜鉛1〜5質量%、
(d)開始剤系、
(e)通常の添加剤、
(f)調節剤、又は調節剤混合物。
2.この混合物を数日間30〜45℃で、大きさ50×50cmのガラス板2枚と、厚さ2.2cmの縁シーリング材から構成されたチャンバで重合させる。引き続きこのコポリマーを、ポリ(メタ)アクリルイミドの目的コポリマーにするために約20時間、40〜130℃にわたる温度プログラムにかける。
これに続く発泡は、数時間にわたって170〜250℃で、好適には200〜250℃で、極めて特に好ましくは220〜250℃で行う。
プラスチックフォーム複合体の製造方法は、以下の工程から成る:
1.プラスチック成形体の製造。このプラスチック成形体は発泡しておらず、機械的手段によって必要な寸法にする。この寸法は、最終的なプラスチックフォーム複合体中で調節すべき発泡密度に従って調整される。コポリマーの密度が分かっている場合には、異方性の発泡特性に基づき、目的密度に対して一定の発泡係数が算出できる。ここから、必要なコポリマーのサイズが計算できる。
2.表層を型に挿入し、プラスチックフォーム複合体の離型を容易にするために任意で、型と表層との間に離型剤を施与することができる。
3.発泡、及び生成する発泡体と1つ若しくは複数の表層との結合は1工程で、170℃〜250℃、好ましくは200℃〜250℃、極めて特に好ましくは220〜250℃の温度で行う。
発泡所要時間は、0.5時間〜5時間であり、好ましくは0.5時間〜4時間、極めて特に好ましくは2時間〜3時間である。
4.冷却後にプラスチックフォーム複合体を、型から取り出すことができる。
実施例1
プラスチック成形体の製造は、DE 199 17 987 A 1の実施例1に記載の処方に従い行う。
直径53.5mm、長さ265mmの円筒形状の型に、その内側にポリアミド製シート(有機プレート:製造元はBrilon在のBond Laminates GmbH社、品番はTEPEX(登録商標)dynalite 102-RG600(1)/47%, 0.50 mm black (PA6 + GF))を、型の内側の縁に接するように置く。この型に、実施例1に記載の組成を有するポリ(メタ)アクリルイミドポリマーを、98×17.5×17.5mmの寸法で置き、この型を約2時間の間、220℃に加熱する。
・部材の密度は、10kg/m3〜300kg/m3の範囲、しかしながら好適には50kg/m3〜200kg/m3の範囲に調整できる。
・部材コア全体では、比較的(この用語については詳細な説明が必要となる)均質な、すなわち閉鎖孔の発泡構造が、特に好ましい方向もなく存在する。
・この部材の特徴は、コア中に均質な気泡サイズ分布を有することである(調整すべき目的密度に応じて気泡の大きさは、0.05〜0.8mmの範囲、好適には0.2〜0.6mmの範囲である)。
・この発泡コアは、ほぼ100%が閉鎖孔構造である。
・表層に対して、非常に良好な結合性/接着性が存在する。以下、「非常に良好な結合性/接着性」とは、表層を剥がすのに必要な力が(測定法は、DIN 53295のTrommel-Schael試験による)、材料固有の剥離モーメントよりも大きいことと理解される。この値はROHACELL(登録商標)については、10〜80Nmm/mmの範囲にある。
・この方法によって、非常に良好な成形が実現される。半径の非常に小さい三次元形状が複製できる(abformen)。
・三次元形状を非常に良好に複製できる。これはつまり、チューブコアと表層の高度な変形レベルが、前記プロセスにより達成されるということである。
・この複合成形体は、平滑な外部皮膜を有する。
・プラスチック複合成形体の場合、非常に良好な繊維固化につながる。発泡プロセスを開始させるため、高温(上記範囲)を部材に導入する。これにより例えば、表層(例えば有機プレート)の熱可塑性マトリックス系において、材料の溶融につながる。さらに、発泡プロセスによって、高い圧力が表層にかかる。これにより、含有される繊維の良好な固化につながる。
・この複合材により、高いエネルギー吸収が可能になる。繊維強化された表層から、また発泡コアからも、高いエネルギー吸収力が得られる:激しいエネルギー作用の場合(例えばクラッシュ)、その強度に達した後に、表層中で亀裂が形成される。この亀裂は、繊維から繊維へ「移動し」、この際にエネルギーを「消費」する。発泡の際には、以下の場合が存在する:その強度を超えると、いわゆる第一セルの崩壊につながる。引き続き、完全なセル平面が崩壊し、それから次から次へと崩壊する。ここで、障害物(崩壊していないセル平面)に繰り返しぶつかることにより、エネルギーが減少する。
直径53.5mm、長さ265mmの円筒形状の型に、その内側にポリアミド製シート(有機プレート:Bond Laminates GmbH社、品番はTEPEX(登録商標)dynalite 102-RG600(1)/47%, 0.50 mm black (PA6 + GF))を、型の内側の縁に接するように平滑に置く。この型に、実施例1に記載の組成を有するポリ(メタ)アクリルイミドポリマーを置く。さらに、寸法が12×12mm(正方形)で長さが245mmの鋼製ロッドを、ポリアミド製シートが鋼製ロッドを取り囲まないように置き、型を約2時間の間、約220℃に加熱する。
・部材の密度は、10kg/m3〜300kg/m3の範囲、しかしながら好適には50kg/m3〜200kg/m3の範囲に調整できる。
・部材コア全体では、比較的均質な、すなわち閉鎖孔の発泡構造が、特に好ましい方向もなく存在する。
・この部材の特徴は、コア中に均質な気泡サイズ分布を有することである(調整すべき目的密度に応じて気泡の大きさは、0.05〜0.8mmの範囲、好適には0.2〜0.6mmの範囲である)。
・この発泡コアは、ほぼ100%が閉鎖孔構造である。
・表層に対して、非常に良好な結合性/接着性が存在する。以下、「非常に良好な結合性/接着性」とは、表層を剥がすのに必要な力が(測定法は、DIN 53295のTrommel-Schael試験による)、材料固有の剥離モーメントよりも大きいことと理解される。この値はROHACELL(登録商標)については、10〜80Nmm/mmの範囲にある。
・この方法によって、非常に良好な成形が実現される。半径の非常に小さい三次元形状が複製できる。鋼製ロッドは、良好に複製される。
・三次元形状の非常に良好な複製ができる。これはつまり、チューブコアと表層の高度な変形レベルが、前記プロセスにより達成されるということである。
・この複合成形体は、平滑な外部皮膜を有する。
・プラスチック複合発泡体の場合、非常に良好な繊維固化につながる。発泡プロセスを開始させるため、高温(上記範囲)を部材に導入する。これにより例えば、表層(例えば有機プレート)の熱可塑性マトリックス系において、材料の溶融につながる。さらに、発泡プロセスによって、高い圧力が表層にかかる。これにより、含有される繊維の良好な固化につながる。
・この複合材により、高いエネルギー吸収が可能になる。繊維強化された表層から、また発泡コアからも、高いエネルギー吸収力が得られる:激しいエネルギー作用の場合(例えばクラッシュ)、その強度に達した後に、表層中で亀裂が形成される。この亀裂は、繊維から繊維へ「移動」し、この際にエネルギーを「消費」する。発泡の際には、以下の場合が存在する:その強度を超えると、いわゆる第一セルの崩壊につながる。引き続き、完全なセル平面が崩壊し、それから次から次へと崩壊する。ここで、障害物(崩壊していないセル平面)に繰り返しぶつかることにより、エネルギーが減少する。
・このプラスチック複合成形体は、曲げ強度とねじり強度が高く、座屈負荷が高く、また耐くぼみ性が非常に良好である。良好な機械的特性は実質的に、サンドイッチ状構造の原則に基づく。 このサンドイッチ状構造は、半製品用の構造様式であり、この様式では、異なる特性を有する複数の層が、1つの材料に埋め込まれている。この構造は非常に頻繁に、繊維複合材料(例えば繊維プラスチック複合材)との組み合わせで適用される。サンドイッチ状構造の構築様式とは軽構造の形態であり、この形態では部材が、力を吸収するトップレイヤーから成り、このトップレイヤーは、比較的軽いコア材料によって距離が保たれている。こうした部材は質量が小さくても、曲げ耐性と耐くぼみ性が非常に高い。その計算は、直線状サンドイッチ理論に従って行う。コア材料は、紙のハニカム、発泡物質(硬質フォーム)、又はバルサ材からなっていてよい。例えば「曲げ」の負荷時においては特に、外側の層が引張力と押圧力を吸収するため、比較的軽い材料製のプレートコアを使用することができ、剪断力の伝達にのみ貢献する。
Claims (7)
- プラスチックフォーム複合成形体の製造方法において、
型に1つ若しくは複数の表層、及び固体のポリ(メタ)アクリルイミドコポリマーを導入し、引き続き当該ポリ(メタ)アクリルイミドコポリマーを発泡させ、前記1つ若しくは複数の表層と結合させることを特徴とする、前記製造方法。 - 前記発泡を、170℃〜250℃の温度で行うことを特徴とする、請求項1に記載の方法。
- プラスチックフォーム複合成形体を1回のみの方法工程で製造することを特徴とする、請求項1に記載の方法。
- 請求項1から3までのいずれか1項に記載の方法により得られるプラスチックフォーム複合成形体。
- 請求項4に記載のプラスチックフォーム複合成形体を、宇宙船、航空機、船舶、及び地上用車両において部材として用いる使用。
- 請求項4に記載のプラスチックフォーム複合成形体を、宇宙船、航空機、船舶、及び地上用車両においてエネルギー吸収性部材として用いる使用。
- 請求項4に記載のプラスチックフォーム複合成形体を、宇宙船、航空機、船舶、及び地上用車両において安定化部材として用いる使用。
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DE201010038716 DE102010038716A1 (de) | 2010-07-30 | 2010-07-30 | Verfahren zum In-Mold Foaming mit einem schäumbaren Medium und Deckschichten und dadurch erhältlicher Kunststoffformkörper |
DE102010038716.9 | 2010-07-30 | ||
PCT/EP2011/058869 WO2012013393A1 (de) | 2010-07-30 | 2011-05-31 | Verfahren zum in-mold foaming mit einem schäumbaren medium und deckschichten und dadurch erhältlicher kunststoffformkörper |
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ZA201300688B (en) | 2013-09-25 |
TR201905418T4 (tr) | 2019-05-21 |
EP2598304A1 (de) | 2013-06-05 |
DK2598304T3 (da) | 2019-05-06 |
WO2012013393A1 (de) | 2012-02-02 |
US20140134422A1 (en) | 2014-05-15 |
CA2807040A1 (en) | 2012-02-02 |
DE102010038716A1 (de) | 2012-02-02 |
EP2598304B1 (de) | 2019-01-16 |
BR112013002196A2 (pt) | 2016-05-31 |
ES2720450T3 (es) | 2019-07-22 |
KR20130132763A (ko) | 2013-12-05 |
AU2011285182A1 (en) | 2013-03-14 |
CN102958662B (zh) | 2016-04-20 |
RU2013108706A (ru) | 2014-09-10 |
TW201221330A (en) | 2012-06-01 |
SG187608A1 (en) | 2013-03-28 |
PL2598304T3 (pl) | 2019-07-31 |
TWI628065B (zh) | 2018-07-01 |
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