Assembling fiber-reinforced foams

Patent metadata

Field	Value
Publication number	US-11890793-B2
Application number	US-201716303447-A
Country	US
Kind code	B2
Filing date	May 17, 2017
Priority date	May 25, 2016
Publication date	Feb 6, 2024
Grant date	Feb 6, 2024

Abstract

The present invention relates to a method for assembling moulded bodies. The invention also relates to a moulded body which comprises a foam and at least one fibre (F), the fibre (F) is within a fibre range (FB2) inside the moulded body and is at least once at least partially divided, wherein at least one fibre (F) is completely divided. The invention further relates to the thus obtained assembled moulded body, and to a panel with contains the assembled moulded body and at least one layer (S1). The invention further relates to a method for producing the panel and to the use of the assembled moulded body and the claimed panel, for example, as a rotor blade in wind turbines.

First claim

The invention claimed is:

1. A process for converting a molding comprising the following steps a) and b):a) providing a molding comprising a foam and at least one fiber (F), wherein the fiber (F) is with a fiber region (FB 2 ) located inside the molding and surrounded by the foam, b) at least partially dividing the molding at least once, wherein at least one fiber (F) is completely divided to obtain a converted molding, wherein in step a) the molding is provided when at least one fiber (F) is partially introduced into the foam with a result that the fiber (F) is with the fiber region (FB 2 ) located inside the molding and surrounded by the foam while a fiber region (FBI) of the fiber (F) projects from a first side of the molding and a fiber region (FB 3 ) of the fiber (F) projects from a second side of the molding and the fiber region (FB 1 ) and/or the fiber region (FB 3 ) are then optionally removed, wherein partial introduction is optionally effected by steps a1) to a6): a1) optionally applying at least one layer (S 2 ) and optionally applying at least one carrier layer (TS) to at least one side of the foam, a2) producing one hole per fiber (F) in the foam and optionally in the layer (S 2 ) and optionally in the carrier layer (TS), wherein the hole extends from a first side to a second side of the foam and optionally through the layer (S 2 ) and optionally through the carrier layer (TS), a3) providing at least one fiber (F) on the second side of the foam, a4) passing a needle from the first side of the foam through the hole to the second side of the foam and optionally passing the needle through the layer (S 2 ) and optionally passing the needle through the carrier layer (TS), a5) securing at least one fiber (F) to the needle on the second side of the foam and a6) returning the needle along with the fiber (F) through the hole, so that the fiber (F) is with the fiber region (FB 2 ) located inside the molding and surrounded by the foam while the fiber region (FB 1 ) of the fiber (F) projects from a first side of the molding or optionally from the layer (S 2 ) or optionally from the carrier layer (TS) and the fiber region (FB 3 ) of the fiber (F) projects from a second side of the molding, wherein the at least partial dividing of the molding in step b) is effected with a cutting tool wherein the at least partial dividing of the molding in step b) is effected without material removal-, wherein the fiber region (FB 1 ) and the fiber region (FB 3 ) each independently of one another account for 0.1% to 45% and the fiber region (FB 2 ) accounts for 10% to 99.8% of the total length of a fiber (F) in step a).

2. The process according to claim 1 , wherein the at least partial dividing of the molding in step b) is effected with a knife.

3. The process according to claim 1 , wherein
i) the at least partial dividing of the molding in step b) is effected at an angle 6 in the range from 0° to 90° relative to the thickness direction (d) of the molding,
ii) the at least partial dividing of the molding in step b) is effected parallel to the first side of the molding, the molding optionally being completely divided parallel to the first side of the molding in step b), or
iii) the molding is partially divided in step b), the molding in step b) being divided at an angle θ in the range from 0° to 45° relative to the thickness direction (d) of the molding, wherein 0.01 to 5 mm or 0.01% to 10%, of the total thickness of the molding remains undivided, or
iv) the molding is partially divided in step b) so that the obtained converted molding comprises units, the units being rectangular or
v) between step a) and step b) at least one carrier layer (TS) is applied to the molding, wherein optionally between step a) and step b) at least one carrier layer (TS) is applied to the molding and in step b) the molding is completely divided, wherein the carrier layer (TS) is not divided, the carrier layer (TS) optionally being open-pored.

4. The process according to claim 1 , wherein the foam has been produced from a particle foam, an extruded foam, a reactive foam or a batch foam.

5. The process according to claim 1 , wherein the foam is based on at least one polymer selected from the group consisting of polystyrene, polyester, polyphenylene oxide, a copolymer produced from phenylene oxide, a copolymer produced from styrene, polyaryl ether sulfone, polyphenylene sulfide, polyaryl ether ketone, polypropylene, polyethylene, polyamide, polyamide imide, polyether imide, polycarbonate, polyacrylate, polylactic acid, polyvinyl chloride, polyurethane, and mixtures thereof.

6. The method according to claim 1 , wherein
i) the fiber (F) in step a) is a single fiber or a fiber bundle, or
ii) the fiber (F) in step a) is an organic, inorganic, metallic or ceramic fiber or a combination thereof, or
iii) the fiber (F) in step a) is employed in the form of a fiber bundle having a number of individual fibers per bundle of at least 10 in the case of glass fibers and 1000 to 50000 in the case of carbon fibers, or
iv) the fiber region (FB 1 ) and the fiber region (FB 3 ) each independently of one another account for 0.1% to 45% and the fiber region (FB 2 ) accounts for 10% to 99.8% of the total length of a fiber (F) in step a), or
v) the fiber (F) in step a) has been introduced into the foam at an angle a of 00 to 600 relative to the thickness direction (d) of the molding or
vi) in the molding in step a) the first side of the molding from which the fiber region (FB 1 ) of the fiber (F) projects is opposite the second side of the molding from which the fiber region (FB 3 ) of the fiber (F) projects or
vii) the molding in step a) comprises a multiplicity of fibers (F) or comprises more than 10 fibers (F) or fiber bundles per m 2 .

7. The process according to claim 1 , wherein the steps a2) and a4) are performed simultaneously.

8. A converted molding obtained by the process according to claim 1 .

9. The converted molding according to claim 8 wherein the converted molding comprises a carrier layer (TS).

10. A panel comprising at least one converted molding according to claim 8 and at least one layer (SI).

11. The panel according to claim 10 , wherein the layer (SI) comprises at least one resin.

12. The panel according to claim 10 , wherein the layer (S 1 ) additionally comprises at least one fibrous material, where
i) the fibrous material comprises fibers in the form of one or more plies of chopped fibers, nonwovens, non-crimp fabrics, knits or wovens, or
ii) the fibrous material comprises organic, inorganic, metallic or ceramic fibers.

13. The panel according to claim 10 , wherein
i) the fiber region (FB 1 ) of the fiber (F) is in partial or complete, preferably complete, contact with the layer (S 1 ), or
ii) the panel comprises between at least one side of the converted molding and at least one layer (S 1 ) at least one layer (S 2 ), wherein the layer (S 2 ) is composed of sheetlike fiber materials or polymeric films, or
iii) the panel comprises two layers (S 1 ) and the two layers (S 1 ) are each attached at a side of the converted molding that is opposite the respective other side of the converted molding, or
iv) the panel has an at least singly curved surface, or
v) the thickness of the panel varies over the width or over the length of the panel by at least 0.5 mm/m.

14. A process for producing a panel according to claim 10 , wherein the at least one layer (S 1 ) is produced, applied and cured on a converted molding in the form of a reactive viscous resin, by liquid impregnation methods.

15. A rotor blade for a wind turbine comprising the converted molding a

Assignees

• Basf Se

Inventors

• Stein Robert
• Ruckdaeschel Holger
• Arbter Rene
• Diehlmann Tim
• Daun Gregor
• Martin Marc Claude

Classifications

• B29C44/5627 Primary

  by mechanical deformation, e.g. crushing, embossing, stretching · CPC title

• B29C44/50

  using pressure difference, e.g. by extrusion or by spraying {(B29C44/468 takes precedence)} · CPC title

• B29C44/54

  in the form of expandable particles or beads · CPC title

• B29C70/086

  and with one or more layers of pure plastics material, e.g. foam layers (applying a non-preformed coating, e.g. a gel-coat, B29C37/0025; with foam blocks B29C70/86) · CPC title

• F03D1/0675

  of the blades · CPC title