• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
  • 法律状态
  • 优先权
    • 专利摘要:
    PURPOSE: A manufacture of form-containing composites is to provide a convenient and economical method of preparing a linear composite and produce a linear composite member having a resin skin and a foam core, with a strong bond between the skin and core. CONSTITUTION: In a method of making a linear composite member, a hollow carrier is provided having a cavity and an inner surface. A curable liquid or gelled resin is applied to the inner surface. A curable foam is introduced into the cavity. The foam contacts the resin when the resin is not more than partially cured, and preferably when the resin has a viscosity not greater than 250,000 centipoise at 25°C. The foam and resin, which are preferably both polyurethanes, are cured together to form a linear composite member having a foam core and a hard resin skin formed integrally.
    公开号:KR20000022359A
    申请号:KR1019980710789
    申请日:1997-07-07
    公开日:2000-04-25
    发明作者:뱌체슬라브 에스 그린쉬펀；케빈 제이 스푸；바이런 헐스
    申请人:휴스톤 로버트 엘；오웬스 코닝；
    IPC主号:
    专利说明:

    Preparation of Composites Containing Foam
    Technical Field
    The present invention generally relates to a process for producing a linear composite having a foam core and a hard resin sheath. In particular, the present invention relates to an economical method for producing such composites in a simple process. The method produces a composite in which the resin envelope is strongly bound to the foam core. The composite has industrial applicability, for example, as an insulating structural member.
    Background of the Invention
    Straight composites with foam cores and hard resin sheaths are useful for a wide range of applications. The hard resin sheath provides strength to the composite so that the composite can be used as a structural member. Due to the foam core, the composite is lightweight and provides heat dissipation and sound insulation. Depending on the application, the composite may have a simple or complex cross sectional shape. For example, the composite can be used as a member of windows, doors, wall panels or roofs, such as building panels or structural panels, building wall materials or vehicle structural panels for use in the building industry.
    Various methods have been used to prepare such composites. In a typical method of making a composite, a foam core is first formed and cured in a foam die. The foam core is then conveyed to a coating chamber where liquid resin is applied to allow the foam core to cure. The composite is then cut to the required length of several pieces. The method has the disadvantage that a series of time-consuming operations are required to produce the composite. As a result, the method may not be as economical as the simple method. Another disadvantage is that the resin applied to the foam core may not be strongly bound to the core. If the resin sheath is loose from the foam core, the composite will not be suitable for the intended application.
    Other methods for forming the complex are known, for example, US Pat. No. 3,533,901 to Sutker, 3,556,888 to Goldsworthy, 3,895,087 to Ottinger et al., 3,895,896 to White et al. Various methods are disclosed for forming complexes in Nos. 4,645,710 and 5,142,835 given to Mrocca. However, such known methods have various drawbacks. Some known methods require the separate formation of a layer of core and shell material or composite, for example in Baitinger et al. Mrocca's patent, where a decorative paper or resin containing fiber mat is attached to the outer surface of the foam core. As an alternative to laminating the film on a supporting substrate or core, Ottinger's patent discloses a molding technique in which a urethane foam core is molded on a preformed plastic film.
    Thus, it would be desirable to provide a straight composite production method that is simple, time-consuming, economical, and produces a composite having a strong bond between the resin sheath and the foam core.
    Summary of the Invention
    It is an object of the present invention to provide a simple and economical method for preparing straight composites. Another object is to produce a linear composite with a resin sheath and a foam core, with a strong bond between the sheath and the core. It is an additional object of the present invention to provide a method that may be used to conveniently form various types of composites. This object is now achieved through the excellent straight composite composite production process according to the invention.
    According to one embodiment of the present invention, the present invention provides a hollow carrier having a cavity and an inner surface, applying a curable liquid or gelled resin to the inner surface, the foam when the resin is only partially cured Introducing a curable foam into the cavity in contact with the cavity and simultaneously curing the foam and the resin to produce a straight composite having an integrally formed foam core and a hard resin sheath. It is about. According to another example of the invention, the invention provides a hollow carrier having a cavity and an inner surface, applying a curable liquid or gelled polyurethane resin to the inner surface, wherein the resin is approximately 50,000 at 25 ° C. introducing a curable foam into the cavity so that the foam contacts the resin when having a viscosity in the range of from about cP to about 100,000 cP and a straight composite having a foam core and a hard resin sheath integrally formed as an outer layer or sheath. It relates to a linear composite production method comprising the step of curing the foam and the resin at the same time to produce.
    In a preferred embodiment, the foam contacts the resin when the resin cures to not more than about 80%. It is preferable to perform the said hardening at normal temperature. The resin sheath may be advantageously covalently bonded to the foam core to form an interpenetrating network with the foam core.
    Preferred resins are polyurethanes. The foam is preferably selected from polyurethanes, isocyanurates, phenol resins, polyimides, epoxies and mixtures thereof. More preferably, the foam is a fast-curing urethane or isocyanate. Polyurethane foam is particularly preferred.
    The carrier is located inside the mold and is preferably a separation material selected from paper and a membrane (eg a polymer membrane). Another preferred material for the carrier is wood veneer. In a preferred embodiment, the resin is retained as the outer surface of the linear composite. The step of applying the resin and introducing the foam preferably comprises the step of releasing the foam or resin through the isolated outlet of the injection device moving relative to the carrier.
    In particular, in one preferred embodiment of the present invention, a hollow carrier having a cavity and an inner surface is provided. A curable liquid resin is applied to the inner surface. Curable foam is introduced into the cavity. When the resin is only partially cured, the foam is in contact with the resin, preferably when the resin has a viscosity of about 250,000 cP or less at 25 ° C. At the same time, the foam and the resin are cured at the same time to produce a straight composite with an integrally formed foam core and a hard resin sheath. Since the resin only partially cures when in contact with the foam, a tight, continuous bond is formed between the resin sheath and the foam core. A reinforcement of material permeable to the resin is placed or fitted in the resin sheath.
    The present invention also relates to a linear composite prepared according to the method described above. This straight composite can be used as a member of windows, doors or roofs, structural or vehicle structural panels, building walls, synthetic wood, and in many other applications. The composite can have a simple or complex cross-sectional shape depending on the application. Preferred composites are used as window wires such as frames or chassis.
    An advantage of the present invention is that the composite may be produced in a single operation rather than a series of operations, and thus the method is simple and economical. The resin sheath is first formed and the foam core is formed just after the same operation. There is no waste of foam material in the production of complex shapes.
    Brief description of the drawings
    1 is a schematic cross-sectional front view of a device for producing a linear composite according to the method of the present invention.
    2 is a schematic front view of an alternative embodiment of a device for producing a linear composite according to the method of the present invention.
    3 is a perspective view of a composite in the form of a window wire prepared according to the method of the present invention.
    4 is a perspective view of an ornari window frame and chassis assembled from a window wire according to the method of the present invention.
    5 is an enlarged cross-sectional front view of a piece of compensating wood veneer suitable for joining as a carrier for an alternative embodiment of a window wire.
    FIG. 6 is a perspective view of a window wire rod having a wood grain finish using the wood veneer carrier of FIG. 5; FIG.
    Detailed Description of the Invention and Preferred Embodiments
    Referring now to the drawings, a method for producing a linear composite 10 according to the present invention is illustrated in FIG. 1. The method is described with reference to preferred apparatus and materials. However, it should be understood that the present invention may be applied to other types of devices and materials.
    In the illustrated method, a die or mold 11 having the required form of the composite is provided. The hollow carrier 12 is located inside the die and takes the form of a die. The carrier has a cavity 13 and an inner surface 14. The carrier can be any material capable of forming the required form of the composite. For example, the carrier may be a separator, such as a silicone separator, a separator, a decorative paper, a decorative plastic or a combination of these materials. If the carrier is a separate material or other relatively rigid material, it is preferred to be placed inside the guide or die as shown to preserve shape until completion of the method. Dies are usually unnecessary when the carrier is a strong, rigid material such as heavy vinyl. The carrier may be removed upon completion of the method or may be retained on the composite as an outer layer, such as a decorative sheath. In another embodiment of the present invention, the method can be performed without the use of a separation material or other carrier material by using a die as a carrier.
    The form of the carrier may be simple or complex depending on the form of the complex. In the complicated form of the window wire described below, the carrier is preferably a separating paper. The method is very economical because there is no waste of foam material when producing complex forms. The cross-sectional shape may generally be rectangular, circular or any other desired shape. The inner surface of the carrier has a pattern like wood grain that is transferred to the resin when the resin is applied to the carrier.
    Curable resin is applied to the inner surface 14 of the carrier. For the present invention, the resin may be present in the liquid state or gelled state. The resin can be applied in a manner such as spraying or wiping to apply the inner surface. In the illustrated embodiment, the resin is applied by the use of the injection device 15. The device has a pair of elongated concentric tubes which are preferably formed of metal. The outer tube with the closed end is the resin conduit 16 to which the resin is supplied. The resin is preferably supplied under pressure by pumping from a storage tank (not shown). If the resin is a two component material such as a polyurethane resin, the two components may be stored in an isolated tank and combined just before being applied to a carrier.
    The resin may also be present in its original solid form and, for example, heated in a storage tank to liquefy before application.
    A plurality of resin outlets 17 are located near the end of the resin conduit 16. A resin outlet is formed around the circumference of the resin conduit such that resin 18 is discharged radially outward from the conduit to the inner surface 14 of the carrier. In a preferred embodiment, the conduit comprises eight resin outlets, showing two of the resin outlets. The resin is preferably released by spraying through the resin outlet. The release rate and release amount can be adjusted using appropriate means to obtain different resin thicknesses. The resin is preferably applied so that the resulting resin shell has a thickness of about 0.5 mm to about 1 cm. In order to apply the resin, the injection device 15 is inserted into the cavity 13 so that the resin outlet is located near one end (left end in FIG. 1) of the carrier. The liquid resin is then sprayed through the resin outlet and the device is pulled through the length of the cavity (to the right when referring to FIG. 1). As a result, the liquid resin is applied to the entire inner surface of the cavity. The carrier is fixed and the device can be fixed while the device is moving relative to the carrier as shown by the arrow in FIG. 1 or while the carrier is moving as shown in FIG.
    The resin can be selected from the group of structural thermoplastic resins and thermosetting resins. Polyurethanes, phenolic resins, polyesters, epoxies, vinyl esters, polyetherketones, polyetherimides, polyethersulfones, high density polyethylene (HDPE), polycarbonates, acrylonitrile-butadiene-styrene (ABS), polypropylene (PP ) And nylon are generally suitable materials. Thermosetting polyesters are preferred because of their short curing time, relatively chemically inertness, and low cost. It is desirable that the resin be cured to form a smooth skin and a firm finish on the finished composite. As will be appreciated by those skilled in the art, accelerators, compatibilizers, fillers, die separation materials, second phases for toughness and coloring agents may be added to the resin.
    Very preferred resins are polyurethanes. This resin can be easily sprayed at room temperature with a short cure time. As is known to those skilled in the art, polyurethanes are prepared by reacting aromatic diisocyanates with diols. One example of a preferred polyurethane is prepared by the catalytic reaction of glycerol and methylene diphenyl diisocyanate (MDI).
    The injection device 15 further comprises an inner tube which is a foam conduit 19. Curable foam is supplied through a foam conduit from any source. Foam is provided by supplying a foamable material from a storage tank (not shown). If the foam is a two component material such as a polyurethane foam, the two components can be stored in an isolated tank and combined just prior to introduction. The foam conduit includes a foam outlet 20 at the end for introduction of the foam into the carrier. Foam conduit 19 extends past the end of the resin conduit 16.
    When the foam 21 is introduced into the cavity 13 of the carrier, the device is pulled through the cavity (to the right in reference to FIG. 1). Due to the structure of the device, resin 18 is applied to the inner surface of the cavity prior to the introduction of the foam. As the resin cures, the foam is introduced and expanded to contact the resin. When the resin is only partially cured, the foam is in contact with the resin, preferably when it is cured to no greater than about 80%. The partially cured resin does not solidify and is still sticky. It is preferred that the foam is in contact with the resin when the resin has a viscosity of less than or equal to about 250,000 cP at 25 ° C., more preferably at or less than about 100,000 cP at 25 ° C. as measured according to ASTM C965. As the foam expands and contacts the partially cured resin, the foam and resin are cured simultaneously and a continuous, tight bond is formed between the resin sheath and the foam core of the composite. If the resin is fully cured when in contact with the foam, the foam and the resin will not form such a good bond. It is preferred that the resin be at least partially cured when the foam contacts the resin so that the resin adheres well to the inner surface of the carrier, and more preferably, the resin has a viscosity of at least 50,000 cP at 25 ° C.
    In addition to the injection device illustrated, other methods may be used to introduce the foam into contact with the partially cured resin. If required or necessary, an electric heating coil or any other suitable method may be provided to keep the resin and foam at high temperature upon curing. However, these materials are preferably cured at room temperature.
    The foam can be selected from any suitable foam material known to those skilled in the art. The foam may be a high density structural foam or a low density insulating foam. The foam is preferably selected from polyurethane foams, polyisocyanurate foams, phenolic resin foams, polyimide foams, epoxy foams, polyurea foams, polyolefin foams, polystyrene foams and mixtures of these materials. Polyurethane foams and polyisocyanurate foams are highly preferred because they cure rapidly at room temperature. Rigid polyurethane foams are well known and commonly prepared from organic polyisocyanates and organic polyols with known blowing agents, surfactants and catalysts. Phenol resin foams are preferred for low smoke generation when burned.
    Optionally, but not limited to water, carbon dioxide, unfluorinated hydrocarbons and HCFCs (ie, hydrochlorofluorocarbons such as dichlorofluoroethane (HCFC 141b) and chlorodifluoroethane (HCFC 142b)); One comprising a fluorinated hydrocarbon such as HFC (ie, hydrofluorocarbons such as 1-fluoro-2-trifluoroethane (HFC 134a) and 1-difluoroethane (HFC 152a)) Various chemical and physical blowing agents can be used to expand the foam. Such blowing agents are available from Allied Signal, Elf Atochem and Dupont.
    In order to increase the stiffness and compressive strength of the composite at a low price, fillers such as sawdust, corn husks, glass waste or silica may optionally be added to the foam. In addition, additives and auxiliaries such as surfactants, catalysts, cell regulators, plasticizers and flame retardants may be included. The specific composition of the foam may be selected, for example, from known compositions and the mixing of the foam components may be accomplished using methods and techniques routinely selected by those skilled in the art.
    In a particularly preferred embodiment, the composite is formed from a polyurethane resin sheath and a polyurethane foam core. When the resin and foam are cured simultaneously, the formation of urethane bonds between the isocyanate in the foam formation and the polyol in the resin formation and vice versa causes the resin and the foam to react to form a tight and continuous bond. In general, where the resin and the foam are materials that can react with each other, the formation of covalent bonds is allowed by curing these materials simultaneously. If the resin and the foam cannot react with each other, the bond formed typically becomes an interpenetrating network.
    If desired, the reinforcement 22 can be fitted to the resin sheath. The reinforcement is typically placed inside the carrier prior to application of the liquid resin. In such a case, the reinforcement must be permeable to the liquid resin to allow the resin to penetrate the reinforcement to the inner surface of the carrier.
    Various materials can be used as the reinforcement material. The reinforcement may comprise any combination of veils made of roving, mat, woven or glass fibers, aramid fibers, carbon fibers, graphite fibers or ceramic fibers. The reinforcement is preferably a web made from polyester or glass fibers.
    2 shows a preferred continuous method of producing a straight composite according to the invention in which the injection device is fixed and the carrier moves relative to the device. A die 23 is provided having the form of the required composite. Two sheets of carrier 24, such as a separator, are withdrawn from the upper and lower carrier rolls 25. The carrier sheet is drawn out through the opening of the molding machine 26 which simultaneously overlaps the sheet to form the desired carrier shape. The carrier is then drawn around the mandrel 27 which positions and positions the carrier for entering the die cavity 28. Similarly, two sheets of reinforcement 29, such as a glass fiber mat, are drawn out of the upper and lower reinforcement rolls 30 around the mandrel through the opening of the molding machine. The reinforcement sheet is located inside the carrier sheet to provide the structure of the reinforcement and the outer carrier near the inner surface of the carrier. An injection device 31 as shown in FIG. 1 is located through the molding machine and the mandrel and extends into the die cavity. As the carrier and reinforcement are withdrawn through the die cavity, the injection device sprays the liquid resin onto the inner surface of the carrier and then introduces the foam into the carrier. The resin is partially cured when in contact with the foam. The resin and foam are simultaneously cured inside the die to form a composite 32 having a hard resin sheath and a foam core. The composite is drawn out by any suitable traction device or take-out device, such as traction drive 33. Next, the composite can be cut to the required length by any suitable means, such as cutter 34. If desired, a finishing and finishing coating such as paint can be applied.
    A preferred composite in the form of a window wire 35 made in accordance with the invention is illustrated in FIG. 3. It can be seen that the window wire comprises a foam core 36 and a hard resin sheath 37 integrally formed with the core. 4 shows a window 38 into which a wire rod such as that shown in FIG. 3 can be integrated. The window generally comprises a rectangular frame 39. When installed in a building, the frame is fixed and located in the opening of the building wall. The frame consists of four straight or linear members 40. The window also generally includes two rectangular chassis 41 located inside the frame. Each chassis has a pane 42 and can slide up and down to open and close the window. Each chassis consists of four straight or linear members 43.
    An alternative embodiment of the composite is a wood shell such as wood veneer in which the carrier is maintained as an outer surface on the composite, illustrated in FIGS. 5 and 6. Wood veneer surfaces are very attractive and are desirable for use on building exteriors. Complementary first and second wood veneer pieces 44 and 45 can be assembled to the carrier as shown in FIG. 1 or can be pulled out of the roll as in the method shown in FIG. Resin is applied to the inner surface of the carrier and foam is introduced into the cavity of the carrier. The resin and the foam are cured at the same time to form a tight bond. As shown in FIG. 5, the result is a composite in the form of a window wire 46 having an outer surface 47, a hard resin sheath 48, and a foam core 49 of wood veneer.
    Typical resin and foam formation is as follows.
    Resin formation
    The resin used in the present invention is prepared by combining the following components (expressed in parts by weight).
    75 Glycerol ("Alkapol SOR 490" available from Rhone Poulenc)
    0.2 Catalyst ("Dabco T9" available from Air Products)
    75 methylene diphenyl diisocyanate (MDI) (“Mondur MR” available from Miles)
    Glycerol and the catalyst are mixed simultaneously at room temperature. MDI is then mixed with glycerol and a catalyst just prior to application of the resin.
    Foam formation
    Foams used in the present invention are prepared by combining the following components (in parts by weight).
    65 sucrose / amine polyol ("Voranol 360" available from Dow Chemical and having a hydroxyl number of 360)
    27.7 polyols (“Alkapol XAP 440” available from Rhone Poulenc and having a hydroxyl number of 440)
    5.0 amine polyols (“Alkapol 770” available from Rhone Poulenc and having a hydroxyl number of 770)
    0.6 water
    1.0 Silicone Surfactant ("Dabco DC5357" available from Air Products)
    0.7 catalyst ("Dabco 33-LV" available from Air Products)
    100 Polymer Isocyanates ("Mondur MR" available from Miles Laboratories)
    Optional examples of foams are prepared from the following components (in parts by weight).
    16.5 polyol flame retardants ("Saytex FR 1138" available from Albemarle)
    24.8 amine polyols (AMG having a hydroxyl number of 370)
    ("Voranol 370" available from Dow Chemical)
    24.0 glycerin polyol ("Terate 203" available from Cape Industries)
    6.8 Glycerin Polyol ("Alkapol 6240", available from Rhone Poulenc and having a hydroxyl number of 240)
    1.2 water
    1.0 Silicone Surfactant ("Dabco DC5357")
    0.7 dimethylcyclohexylamine (DMCHA) ("Polycat 8" available from Air Products)
    7.0 trichlorofluoromethane ("CFC 11" available from Elf Atochem)
    82.7 Polymeric Isocyanates ("Mondur MR" available from Miles Laboratories)
    In foam preparation, all components except polymeric isocyanates are mixed simultaneously at room temperature. The isocyanate is then mixed with the other components just prior to the introduction of the foam into the carrier.
    The foregoing detailed description and the preferred embodiments and features have been provided to illustrate the invention. Intuitive variations will be apparent to those skilled in the art. Therefore, it is to be understood that the invention is defined not by the foregoing description but by the appended claims and their equivalents.
    权利要求:
    Claims (20)
    [1" claim-type="Currently amended] As a linear composite production method,
    Providing a hollow carrier having a cavity and an inner surface,
    Applying a curable liquid or gelled resin to the inner surface,
    Introducing the curable foam into the cavity such that the foam contacts the resin when the resin is partially cured,
    And simultaneously curing the foam and the resin to produce the linear composite having an integrally formed foam core and a hard resin sheath.
    [2" claim-type="Currently amended] The method of claim 1 wherein the resin is a liquid resin and the foam is in contact with the resin when the resin cures to about 80% or less.
    [3" claim-type="Currently amended] The method of claim 1 wherein the foam is in contact with the resin when the resin has a viscosity at 25 ° C. of about 250,000 cP or less.
    [4" claim-type="Currently amended] 2. The method of claim 1, wherein the resin sheath is covalently bonded to the foam core.
    [5" claim-type="Currently amended] The method of claim 1, further comprising positioning a reinforcing material in the resin.
    [6" claim-type="Currently amended] The method of claim 5, wherein the reinforcing material is a linear composite manufacturing method, characterized in that the resin can penetrate.
    [7" claim-type="Currently amended] The method of claim 1, wherein the resin is a polyurethane composite production method characterized in that the polyurethane.
    [8" claim-type="Currently amended] The method of claim 1, wherein the foam is selected from the group consisting of polyurethane, isocyanurate, phenol resin, polyimide, epoxy, and mixtures thereof.
    [9" claim-type="Currently amended] 9. The method of claim 8, wherein the curing step is carried out at room temperature.
    [10" claim-type="Currently amended] 2. The method of claim 1, wherein applying the resin and introducing the foam comprise discharging the foam or the resin through an isolated outlet of an injection device that is relatively moved relative to the carrier. Characterized in that the linear composite production method.
    [11" claim-type="Currently amended] The method of claim 1, wherein the carrier is a separation material selected from the group consisting of paper and membrane, and the separation material is located inside the mold.
    [12" claim-type="Currently amended] The method of claim 1 wherein the carrier is retained as an outer surface on the straight composite.
    [13" claim-type="Currently amended] 13. The method of claim 12 wherein the carrier is wood veneer.
    [14" claim-type="Currently amended] As a linear composite production method,
    Providing a hollow carrier having a cavity and an inner surface,
    Applying a curable liquid or gelled polyurethane resin to the inner surface,
    Introducing the foam into the cavity, wherein the foam is curable so that the foam contacts the resin when the resin has a viscosity in the range of about 50,000 cP to about 100,000 cP at 25 ° C.,
    And simultaneously curing the foam and the resin to produce the linear composite having an integrally formed foam core and a hard resin sheath.
    [15" claim-type="Currently amended] 15. The method of claim 14 wherein the foam is polyurethane.
    [16" claim-type="Currently amended] A linear composite produced according to the method according to claim 1, comprising an integrally formed foam core and a hard resin sheath.
    [17" claim-type="Currently amended] 17. The composite of claim 16 wherein said resin sheath is covalently bonded to said foam core.
    [18" claim-type="Currently amended] 18. The composite of claim 17 wherein said foam core and said resin sheath are simultaneously bonded by urethane bonds.
    [19" claim-type="Currently amended] 17. The composite of claim 16, wherein said resin sheath forms an interpenetrating network with said foam core.
    [20" claim-type="Currently amended] The composite according to claim 16, wherein the composite is a member selected from the group consisting of window members, door members, roof members, building wall materials, building structural panels and vehicle structural panels.
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    同族专利:
    公开号 | 公开日
    CA2259687A1|1998-01-15|
    US5807514A|1998-09-15|
    EP0912313A1|1999-05-06|
    JP2000514729A|2000-11-07|
    EP0912313A4|1999-07-07|
    WO1998001279A1|1998-01-15|
    引用文献:
    公开号 | 申请日 | 公开日 | 申请人 | 专利标题
    法律状态:
    1996-07-10|Priority to US8/677,692
    1996-07-10|Priority to US08/677,692
    1997-07-07|Application filed by 휴스톤 로버트 엘, 오웬스 코닝
    2000-04-25|Publication of KR20000022359A
    优先权:
    申请号 | 申请日 | 专利标题
    US8/677,692|1996-07-10|
    US08/677,692|US5807514A|1996-07-10|1996-07-10|Manufacturing of foam-containing composites|
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