DE102011080906A1 - Device for applying intumescent reaction mixtures - Google Patents

Abstract

The invention relates to a device, comprising at least a mixing head and a discharge line, for applying intumescent reaction mixtures to a substrate, wherein at least the passing of the intumescent reaction mixture in contact parts of the outlet line (s) of a thermoplastic polyurethane (TPU) based on polyether polyol a release agent content between 0.30 mass% and 2.0 mass%, preferably between 0.35 mass% and 1.5 mass%, particularly preferably between 0.40 mass% and 1.0 mass%, based on the total mass of the TPU according to the invention, and the use of this device in the production of composite elements.

Description

The invention relates to a device, comprising at least a mixing head and a discharge line, for applying intumescent reaction mixtures to a substrate, wherein at least the passing of the intumescent reaction mixture in contact parts of the outlet line (s) of a thermoplastic polyurethane (TPU) based on polyether polyol a release agent content between 0.30 mass% and 2.0 mass%, preferably between 0.35 mass% and 1.5 mass%, particularly preferably between 0.40 mass% and 1.0 mass%, based on the total mass of the TPU according to the invention, and the use of this device in the production of composite elements.

Sandwich composite elements comprising two cover layers and an intermediate core layer of a foam, are exposed to a variety of requirements, in particular increasing requirements for fire resistance at low element thicknesses, optimized smoking behavior and an efficient thermal insulation. In addition, the market demands increasing productivity in the production of sandwich composite elements with simultaneously high surface quality of the outer layers. In this context, there is a need for improved sandwich composite fabrication processes which provide high speed and reliability in production. Of particular importance in this case is the distributor device for applying the foamable material to the cover layer (the substrate).

Distributor devices for applying foamable reaction mixtures to substrates in general have in principle been known for some time, for example US 4,624,213 . DE 31 51 511 A1 and GB 1,197,221 , None of these documents discuss how a consistent production process can be maintained over a longer period of time (for example, a production shift of approximately eight hours) without problems due to clogging by intumescent material.

For the continuous production of sandwich composite elements in particular oscillating mixing heads are known from the prior art. Here, the mixing head performs an oscillating movement across the width of a lower cover layer and carries the still liquid reaction mixture by means of a casting rake or tongue / spoon nozzle, which is arranged at right angles to the mixing head and parallel to the lower cover layer, on the lower cover layer.

The mixing head is attached to a guide rail, the so-called portal, above the lower cover layer and is accelerated by means of electric motors and braked before the reversal points. The foaming raw materials are supplied to the mixing head via hose lines. Furthermore, some hydraulic or pneumatic hoses lead to the mixing head. The foaming raw materials are introduced into the mixing head via nozzles and mixed.

The reaction mixture then flows into the casting rake and exits at the regularly placed holes. Due to the length of the casting rake and its bores, as well as the oscillating movement of the mixing head, a distribution of the reaction mixture lying at an angle to the direction of production is achieved.

After application, the reaction mixture foams up and rises to the upper surface layer. In the foaming process, it adheres the two outer layers before the foam solidifies and hardens.

This production process is limited in production terms in terms of production speed. Even if sufficiently powerful motors, guide rails, hoses, mixing heads and casting rakes or tongue / spoon nozzles were used, the reaction mixture would be carried out due to excessive centrifugal forces at the reversal points over the edges of the outer layers. According to the state of the art, production speeds of more than 15 m / min can not be achieved in the continuous production of sandwich composite elements with this application technique.

It is well known to increase the production speed to up to 60 m / min by means of stationary mixing head technology and rigid discharge systems ( Rubber Rubber Plastics, Volume 57, No. 4/2004 ). This technology consists essentially of three equal feed lines with separate feed and separate mixing heads and exit systems. However, this technology does not have a distributor head. This method has the further disadvantage that the respective exiting reaction mixture from the individual mixing heads can also be subject to different physical conditions with respect to pressure and temperature, resulting in each foam obtained by Product quality reductions such as uneven surface, smaller cells, different thermal conductivity values due to punctually different reaction kinetics, makes noticeable.

EP 1 857 248 A2 solves this problem in that not every outlet has a separate mixing head. Rather, only a central mixing head is provided, are fed via the multiple outlet lines. The material of the outlet lines is only subject to the restrictions that it should not react with the reaction mixture to be foamed and should not disproportionately adhere to it (see column 3, lines 36 to 50). The use of thermoplastic polyurethanes is not disclosed in this context.

WO 2008/018787 A1 relates to a device for applying a viscous mixture on a surface by means of one or more outlet openings, which are fed by a feed element. The document further relates to a method for producing an insulating element comprising the steps of applying a viscous mixture which forms a foam on a substrate layer, wherein the foam is then crosslinked and optionally the foam layer is further coated. A mixing head 3 is supplied with components from the feeders 1 and 2 with raw material. A casting rake 6 is controlled by a plurality of intermediate webs 5 via a sub-distribution 4 via a rigid main line 8. The casting rake is thus rigidly connected to the mixing head, can only be moved completely with the mixing head to the left or right in order to adjust the application area as a whole in the correct position to the substrate can. In addition, the cleaning of the system is very expensive.

WO 2008/104492 A2 discloses a method for producing composite elements, wherein the application of the liquid starting material for the isocyanate-based rigid foam by means of a fixed, parallel and perpendicular to the direction of movement to the cover layer mounted, provided with bored pipe.

WO 2009/077490 A2 discloses a method for producing composite elements in which a tube-like casting rake with holes at the bottom, distributed over the entire length, is used, and wherein the application of the liquid starting material for the rigid foam takes place parallel to the top layer plane and at right angles to the direction of movement.

WO 2010/108615 A1 discloses a method for producing intumescent composite elements, in which a device comprising a mixing head, a distributor head with at least two hose lines and at least two stationary casting rakes is used. The material of the hose assemblies is subject only to the restrictions that it should not react with the reaction mixture to be foamed and should not disproportionately adhere to it (see page 6, lines 9 to 17). The use of thermoplastic polyurethanes is not disclosed in this context.

In all the above-mentioned prior art methods, it can easily happen that the availability of the distributor device for the material to be foamed is reduced by blockages, in particular of supply lines and / or hoses, which leads to loss of production and time-consuming cleaning operations.

Taking into account these difficulties of the prior art processes, it is an object of the present invention to provide apparatuses and methods which enable the application of foamable materials to suitable substrates at a high production rate while maintaining high reliability and device availability and higher, throughout the production process consistent, product quality, in particular with regard to the surface quality of the foam to be produced, can achieve. In particular, the continuous production of composite elements should be improved in this sense.

• (a) einen Mischkopf M zum Vermischen der zur Herstellung eines Schaumstoffs erforderlichen Rohmaterialien,
• (b) mindestens eine Abgangsleitung A für das aufschäumende Reaktionsgemisch,

wobei mindestens die mit dem aufschäumenden Reaktionsgemisch in Kontakt tretenden Teile der Abgangsleitung(en) aus einem thermoplastischem Polyurethan auf Polyetherpolyol-Basis gefertigt sind, welches wenigstens ein Trennmittel in einem Gehalt von 0,30 Massen-% bis 2,0 Massen-%, bevorzugt 0,35 Massen-% bis 1,5 Massen-%, besonders bevorzugt 0,40 Massen-% bis 1,0 Massen-%, bezogen auf die Gesamtmasse des thermoplastischen Polyurethans auf Polyetherpolyol-Basis, enthält.An object of the invention is therefore an apparatus for applying intumescent reaction mixtures to a substrate comprising:

• (a) a mixing head M for mixing the raw materials required to produce a foam,
• (b) at least one outlet line A for the intumescent reaction mixture,

wherein at least the parts of the outlet line (s) which come into contact with the intumescent reaction mixture are made from a polyether polyol-based thermoplastic polyurethane which comprises at least one release agent in a content of 0.30 mass% to 2.0 mass% 0.35 mass% to 1.5% by mass, particularly preferably 0.40% by mass to 1.0% by mass, based on the total mass of the thermoplastic polyurethane based on polyetherpolyol.

The invention further relates to the use of the device according to the invention in the production of composite elements comprising a foam layer on a substrate.

In the context of the present invention, an intumescent reaction mixture is to be understood as meaning mixtures of raw materials which react to form a foam, for example mixtures of polyols and di- or polyisocyanates, if appropriate with the addition of a blowing agent and / or co-blowing agent and further auxiliary and additives.

Depending on the technology used ("high-pressure" or "low-pressure"), a mixing head according to the present invention can be designed as a dynamic mixer basically known to the person skilled in the art or as a static mixer. It serves the intimate mixing of the respective raw materials. The mixing head must be suitable for the respective foaming task. It is easy for a person skilled in the art to select the mixing head suitable for a specific foaming task. In the device according to the invention, the mixing head is preferably mounted above the substrate on a rigid frame, so that different reaction profiles for the production of different thickness products are possible.

The intumescent reaction mixture is distributed over the outlet line (s) on the substrate. The outgoing lines may be pipes or hoses, for example. It is only essential in this connection that the parts of the outlet lines which come into contact with the intumescent reaction mixture are made of the thermoplastic polyurethane according to the invention. This can be achieved by making the entire outgoing line of this material (eg hoses made of thermoplastic polyurethane according to the invention). Alternatively, only the interior of the outlet conduit may also be coated with the thermoplastic polyurethane according to the invention (eg metal tubes with a coating of the thermoplastic polyurethane according to the invention).

For the purposes of the present invention, thermoplastic polyurethane (in contrast to ordinary polyurethane) is understood as meaning a material comprising urethane structures which can be repeatedly softened under the influence of temperature and pressure. Thermoplastic polyurethanes (also referred to below as TPU) per se have long been known; they are z. In the Polyurethane Handbook, Günter Oertel, Carl Hanser Verlag, 1985, p 405 to p 417 described in detail.

The TPU types which can be used according to the invention are those based on polyetherpolyol. This means that they are obtained by reacting suitable isocyanates (see below for details) with polyether polyols. The inventively employable polyether polyols contain the structural element -CHR ¹ - (CH ₂ ) _m -CHR ² -O-, as repeating unit, wherein R ¹ and R ² independently represent hydrogen, an alkyl or aryl group having 1 to 6 carbon atoms with or without halogen substitution, and wherein m is an integer between 0 and 2. Preferred polyether polyol is polytetrahydrofuran (R ¹ = R ² = H, m = 2). The concomitant use of other polyol types (for example polyesterpolyols) in the preparation of the thermoplastic polyurethanes according to the invention is not required, but does not interfere to a limited extent either. Such admixtures of other types of polyol are at most 10% by mass, preferably at most 5% by mass, more preferably at most 1% by mass, based on the total mass of all polyols used in the preparation of the thermoplastic polyurethanes according to the invention.

A material is referred to in the context of the present invention as being made of a thermoplastic polyether-polyol-based polyurethane if it is at least 90% by mass, preferably at least 95% by mass, more preferably at least 99% by mass, and most preferably completely made of this thermoplastic polyether-polyol based polyurethane.

In the context of this invention, a release agent is understood as meaning a constituent of the thermoplastic polyurethane which is intended to prevent it from sticking to the surrounding material (cf. EP 0 792 917 B1 , P. 2 paragraphs [0004] and [0005]). Such release agents are z. B. fatty acid esters and their metal soaps, besides fatty acid amides and oleic acid amides, or polyethylene waxes. It is also possible to use mixtures of different release agents. In this case, the information refers to 0.30 mass% to 2.0 mass %, preferably 0.35 mass% to 1.5 mass%, particularly preferably 0.40 mass% to 1.0 mass%, on the sum of all release agents.

The intumescent reaction mixture is applied to a substrate to which the respective foam adheres, optionally with the aid of an adhesion promoter, preferably in such a way that no unwetted areas are formed. Suitable substrates in the context of the present invention, for example, surfaces of metal, wood, cardboard, paper, bitumen u. a.

Hereinafter, various embodiments of the device according to the invention will be described in detail. In this case, the individual embodiments can be combined freely with each other, unless clearly the opposite results from the context.

In preferred embodiments, the reaction mixture in the mixing head or at least one of the raw materials used prior to feeding into the mixing head under elevated pressure (preferably from 6.0 bar to 12 bar (absolute)) gas, which under the given conditions of temperature and pressure not may react with the raw materials and the foam to be formed. Preferably, this gas is selected from the group of air, nitrogen, carbon dioxide and noble gases (eg argon and helium). Preferably, air is used. After the gas has been introduced, the mixture of the raw materials and the added gas on its way to the mixing head (and from there via the distributor head via the discharge lines to the substrate) has an elevated pressure, which causes an increased discharge rate of the intumescent reaction mixture. In addition, the addition of a pressurized gas improves product quality. Instead of a gas or in addition to it, other constituents of the reaction mixture can be admixed. These substances are selected by way of example from the group of graphite, polyurethane flour, melamine, quartz sand, Al ₂ O ₃ , talc and nanocomposites such as, for example, phyllosilicates, nanotubes, nanosand; they are preferably added to the reaction mixture in the mixing head. However, it is also conceivable to interfere with the reaction mixture stream leaving the mixing head.

• (a) einen Mischkopf M zum Vermischen der zur Herstellung eines Schaumstoffs erforderlichen Rohmaterialien,
• (aa) einen strömungstechnisch hinter dem Mischkopf liegenden Verteilerkopf V, an dem
• (b) zwei bis zehn, bevorzugt drei bis acht, Abgangsleitungen A für das aufschäumende Reaktionsgemisch angebracht sind,

wobei mindestens die mit dem aufschäumenden Reaktionsgemisch in Kontakt tretenden Teile der Abgangsleitung(en) aus einem thermoplastischem Polyurethan auf Polyetherpolyol-Basis gefertigt sind, welches wenigstens ein Trennmittel in einem Gehalt von 0,30 Massen-% bis 2,0 Massen-%, bevorzugt 0,35 Massen-% bis 1,5 Massen-%, besonders bevorzugt 0,40 Massen-% bis 1,0 Massen-%, bezogen auf die Gesamtmasse des thermoplastischen Polyurethans auf Polyetherpolyol-Basis, enthält.In a further preferred embodiment, the device comprises a plurality of outlet lines. In this case, the mixing head is followed by a distributor head, to which the outgoing lines are attached. In this embodiment, the device according to the invention comprises

• (a) a mixing head M for mixing the raw materials required to produce a foam,
• (aa) a fluidically behind the mixing head lying distributor head V, on the
• (b) two to ten, preferably three to eight, outlet lines A are provided for the intumescent reaction mixture,

wherein at least the parts of the outlet line (s) which come into contact with the intumescent reaction mixture are made from a polyether polyol-based thermoplastic polyurethane which comprises at least one release agent in a content of 0.30 mass% to 2.0 mass% 0.35% by mass to 1.5% by mass, particularly preferably 0.40% by mass to 1.0% by mass, based on the total mass of the thermoplastic polyurethane based on polyetherpolyol.

In the embodiment of the device according to the invention with only one outlet line A, the distributor head V is dispensable. In this case, the one outlet line is preferably attached to the mixing head itself. However, an embodiment of the device in which a plurality, in particular two to ten, preferably three to eight, outgoing lines A are attached to a distributor head V is preferred. If the distributor head is described lying in fluid flow behind the mixing head in this context, then this is to be understood in relation to the flow direction of the material flowing through these two heads. First, the mixing head and then the (preferably attached to) distributor head are flowed through.

The intumescent reaction mixture, optionally comprising an added gas or one of the abovementioned solid constituents, is distributed, if appropriate via the distributor head V, to the at least one, preferably at least two to ten, particularly preferably three to eight discharge lines. The materials of the mixing and, if necessary, distributor head are selected independently from one another preferably from steel, stainless steel, aluminum and plastics (for example polyethylene, polypropylene or polytetrafluoroethylene.) In preferred embodiments, these materials may be coated internally with TPU according to the invention Material to withstand the usual absolute pressures prevailing in the mixing head (in the range of about 3 bar to 10 bar) and temperatures (in the range of 20 ° C to 40 ° C.) In the case of multiple outgoing lines, the geometry of the distributor head is preferably selected so that the ones from foaming reaction mixture zurückzulegende distance to impinge on the substrate regardless of which outlet line is flowed through, is the same length. Furthermore, it is advantageous if the cross section of the distributor head exits is identical for all distributor head outlets. On the other hand, the cross section of the distributor head entrance can be larger than the respective distributor head exits.

The polyether polyol-based thermoplastic polyurethanes (TPUs) to be used according to the invention fulfill the requirements which must be imposed on a material from which outlet lines are to be made (chemical inertness towards the intumescent reaction mixture and low adhesion) is extraordinarily good. In particular, it has also been found that the clogging of outlet lines by already formed foam can be largely or completely prevented by the use of these polyether polyol-based TPU types.

Due to the excellent material properties of these types of TPUs, in preferred embodiments, the present invention also encompasses such a device for applying intumescent reaction mixtures to a substrate, in which all parts coming into contact with the intumescent reaction mixture, namely mixing head, optionally distributor head, outlet lines and optionally Casting raking (see below for details) of the polyether polyol-based thermoplastic polyurethane which comprises at least one release agent in a content of 0.30 mass% to 2.0 mass%, preferably 0.35 mass% to 1.5% by mass, particularly preferably 0.40% by mass to 1.0% by mass, based on the total mass of the thermoplastic polyurethane based on polyetherpolyol, containing, manufactured or internally coated. In the case of the mixing head, possibly existing distributor head and possibly existing casting rakes, it is preferable to manufacture them from steel, stainless steel, aluminum and plastics (such as polyethylene, polypropylene or polytetrafluoroethylene) and to coat them internally with TPU according to the invention.

These polyether polyol-based TPU types are obtained in a preferred embodiment by reacting a diisocyanate (or mixtures of diisocyanates) with a polyether polyol (or mixtures of polyether polyols). Particular preference is given to such an embodiment of the device according to the invention, in which the thermoplastic polyether-based polyol is obtained by reacting at least one polyether polyol having a molecular weight between 800 g / mol and 5000 g / mol, preferably between 900 g / mol and 1500 g / mol in the presence of at least one chain-extending diol having a molecular weight below 500 g / mol with at least one diisocyanate.

In the context of this invention, the term "molar mass" means the exact molar mass, provided that these are precisely defined diols and polyols whose exact molar mass can be calculated. If it is not possible to determine the exact molar mass of a diol or polyol in the context of this invention, the number-average molar mass M _n , determined by gel permeation chromatography, is DIN 55672-1 from August 2007, authoritative. This applies to all types of di- and polyols for all articles of the invention and for all embodiments.

In addition to the aforementioned polyols and diols, 0.003 mole to 0.08 mole may be included per mole of the chain extending diol of a monofunctional chain terminator of the general structural formulas R ³ -OH, R ⁴ -NH ₂ or R ⁴ -NH-R ⁵ , where R ³ , R ⁴ and R ^{5 is} a straight or branched hydrocarbon chain having 1 to 30 carbon atoms, which may optionally contain oxygen, sulfur or other heteroatoms mean, and the molar ratio NCO / (OH + NH), multiplied by 100, the so-called Index, between 96 and 108, preferably between 98 and 106.

For the preferred preparation of the thermoplastic polyurethanes according to the invention based on polyether polyol from Poyetherpolyolen and diisocyanates come as starting components on the isocyanate especially the technically readily available diisocyanates such as 2,4- and 2,6-toluene diisocyanate and mixtures thereof, the 4.4 '- And the 2,4'-diphenylmethane diisocyanate or mixtures thereof, the 4,4'-diisocyanato-dicyclohexylmethane, and the 1,6-diisocyanatohexane used. Preference is given to 4,4'-diphenylmethane diisocyanate used.

For the preferred preparation of the polyether polyol-based thermoplastic polyurethanes according to the invention from polyether polyols and diisocyanates, the starting materials used on the polyol side are in particular the polyaddition products of epoxides such as ethylene oxide, propylene oxide, butylene oxide, tetrahydrofuran, styrene oxide or epichlorohydrin. These epoxides are either with themselves, z. B. in the presence of catalysts, or polymerized by addition of these epoxides, optionally in admixture or sequentially, to starting components with reactive hydrogen atoms such as alcohols or amines, for. As water, ethylene glycol, propylene glycol (1,3) or - (1,2) 4,4'- Dihydroxydiphenylpropane, aniline, ethanolamine or ethylenediamine, polymers shown. In both variants, preference is given to using ethylene oxide, propylene oxide and tetrahydrofuran, particularly preferably tetrahydrofuran. In all variants, the average functionalities of the polyether polyols according to the invention are preferably between 1.5 and 3.

As chain-extending diols having molecular weights below 500 g / mol are preferably ethylene glycol, diethylene glycol, butanediol, hexanediol, octanediol, decanediol and dodecanediol and hydroquinone bis (2-hydroxyethyl ether) into consideration.

DE 24 18 075 A1 describes inter alia lined polyurethanes based polyurethanes, which, if in addition a release agent content between 0.30 mass% and 2.0 mass%, preferably between 0.35 mass% and 1.5 mass%, more preferably between 0.40 mass% and 1.0 mass% is set (the release agent content plays no role in the cited document) can be used according to the invention. The particular properties of the polyether-based thermoplastic polyurethanes with a specified release agent content, which qualify them for use in the device according to the invention are not disclosed in this document. The release agent to be used according to the invention is preferably selected from the group of the fatty acid esters, their metal soaps, fatty acid amides, polyethylene waxes and mixtures of the abovementioned compounds. Specific examples of preferred compounds are stearic acid esters and montanic acid esters and their metal soaps, along with stearylamides and oleic acid amides. Ethylene-bis-stearylamide, the diamide of ethylenediamine with steraric acid, is particularly preferably used.

The thermoplastic polyurethane according to the invention can advantageously be prepared continuously by feeding the components by means of metering pumps to a mixing device where they are intimately stirred. It is particularly advantageous if the reacting mixture from this mixing device is applied to heated plates or strips, optionally equipped with separating agents. In a further advantageous variant, the thermoplastic polyurethane according to the invention can continuously in the so-called extruder process, for. B. in a multi-screw extruder, in which the components isocyanate, polyether polyol and chain-extending diol are reacted, are prepared (see. EP 0 792 917 B1 , in particular p. 5, paragraphs [0027] and [0028]). The dosage of the release agent can be metered continuously to the TPU reaction in the extruder. But it is also possible to dose the release agent in the previously prepared and melted in an extruder thermoplastic polyurethane and compounding. However, the release agent can also be mixed in a further variant prior to the reaction with the thermoplastic polyurethane with the polyether polyol and then fed to it with the reaction.

In addition to the release agent used, the thermoplastic polyurethane according to the invention also antioxidants and other auxiliaries, such as. As plasticizers, are added. Typical plasticizers are, for example, benzoates, phthalates or phosphoric esters.

In order to ensure that the amount of intumescent reaction mixture applied to the substrate per unit of time is distributed as homogeneously as possible, it is preferred to use such a device for applying intumescent reaction mixtures to a substrate in which the outlet lines attached to the distributor head have the same length have the same cross section and their parts in contact with the intumescent reaction mixture of the same material (ie, the same type of thermoplastic polyether polyol-based polyurethane). This embodiment can be combined with all the aforementioned embodiments.

A particularly advantageous distribution of the foaming reaction mixture onto the substrate can be achieved if each discharge line opens into a casting rake G known to those skilled in the art, each casting rake having between 5 and 100, preferably 5 and 50, outlet openings for the intumescent reaction mixture, depending on the size. This embodiment can also be combined with all the aforementioned embodiments. Structure and arrangement of the casting rakes in the context of the present invention are preferably as in WO 2010/108615 A1 on page 3, lines 35 to 4, line 25, on page 5, lines 4 to Z. 13 and on page 6, lines 26 to 7, Z.7. The casting rakes may be of the same material as the mixing and dispensing head (see above).

The device according to the invention is outstandingly suitable for use in processes for the production of composite elements comprising a foam layer on a substrate in all of the abovementioned embodiments. Another object of the present invention is therefore the use of the above described apparatus for applying intumescent reaction mixtures to a substrate in the production of composite elements comprising a foam layer on a substrate.

In a preferred embodiment, the substrate is moved (for example by means of a conveyor belt in a predetermined direction). In this case, the outgoing lines are preferably arranged and fixed on a rigid frame arranged transversely to the direction of movement of the substrate. As a result, uniform over the width of the substrate uniform order is guaranteed.

The reaction of the raw materials in the production of the composite elements is preferably carried out continuously, wherein the raw materials are fed by metering pumps to the mixing head and intimately mixed there.

Particularly preferred is the use of the device according to the invention in the production of the so-called sandwich composite elements, ie composite elements containing two outer layers and a core layer located therebetween, in the present case, a foam layer. The lower cover layer is the substrate to which the foam layer is applied. The foam layer is in turn bounded by the upper cover layer. Another object of the present invention is therefore the use of the previously described apparatus for applying intumescent reaction mixtures to a substrate in the manufacture of composite elements, wherein the composite element is a sandwich composite element, wherein the foam layer between the substrate (the lower cover layer) and an upper cover layer is arranged. Between the substrate and the foam, other layers may be arranged.

Preferred foams are polyurethane foam, polyisocyanurate foam, polystyrene foam and phenolic foam. Particular preference is given to "rigid polyurethane foams", which are to be understood as meaning rigid foams based on polyurethane, polyurea and / or polyisocyanurate compounds.

In the case of PUR rigid foams as the core layer, as raw materials for the foam layer of the composite element or sandwich composite element, at least one isocyanate component ("Component A") and at least one polyol component ("Component B") are used. In this context, the terms "isocyanate component" and "polyol component" also include mixtures of different isocyanates or polyols.

The raw materials react with each other when applied to the substrate to form the foam core layer. This foaming of isocyanate and polyol component is preferably carried out at an index of 100 to 400. The index denotes the molar ratio of the isocyanate groups to the isocyanate-reactive hydrogen atoms multiplied by 100.

The organic isocyanate component used are aliphatic, cycloaliphatic, araliphatic, aromatic and heterocyclic polyisocyanates, preferably mixtures of isomers of diphenylmethane diisocyanate (MDI) and its oligomers (polyphenylpolymethylene polyisocyanate, PMDI). It is likewise possible to use carbodiimide groups, urethane groups, allophanate groups, isocyanurate groups, urea groups or biuret group-containing polyisocyanates, particularly preferably those based on polyphenylpolymethylene polyisocyanate. In addition, the use of suitable NCO prepolymers prepared from the reaction of PMDI with aliphatic or aromatic polyether polyols or polyester polyols, for example 1 to 4 hydroxyl-containing polyether polyols or polyester polyols having a molecular weight of 60 g / mol to 4000 g / mol is possible.

The polyol component contains compounds with isocyanate-reactive hydrogen atoms, such as polyether polyols, polyester polyols or polyester ethers. Such compounds are known in the art and, for example, in Mihail Ionescu, Chemistry and Technology of Polyols for Polyurethanes, Rapra Technology Limited, 2005, pp. 321-366 and pp. 419-431 described. Preference is given to using compounds which have a functionality of 1.8 to 4.5, a hydroxyl number of 20 to 600 mg KOH / g and optionally primary OH groups. In addition, the polyol component may still contain low molecular weight chain extenders or crosslinkers. These additives can effect an improvement in the flowability of the reaction mixture and the emulsifiability of the blowing agent-containing formulation on continuously producing plants on which elements with flexible or rigid cover layers are produced.

As a rule, flameproofing agents are added to the intumescent reaction mixture of isocyanate and polyol components, preferably in an amount of 5 to 35% by mass, based on the total mass of compounds having isocyanate-reactive hydrogen atoms in the polyol component. Such flame retardants are known in the art in principle and, for example, in Polyurethane Handbook, Günter Oertel, Carl Hanser Verlag, 1985, Chapter 6.1, p. 270 described. These may be, for example, bromine- and chlorine-containing polyols or phosphorus compounds such as the esters of orthophosphoric acid and metaphosphoric acid, which may also contain halogen. Preferably, liquid flame retardants are selected at room temperature.

As the foaming reaction mixture of isocyanate and polyol component added blowing agent hydrocarbons, eg. As the isomers of pentane or fluorocarbons, eg. HFC 245fa (1,1,1,3,3-pentafluoropropane), HFC 365mfc (1,1,1,3,3-pentafluorobutane) or mixtures thereof with HFC 227ea (heptafluoropropane). It is also possible to combine different propellant classes.

As co-blowing agents added to the intumescent reaction mixture of isocyanate component and polyol component, water and / or formic acid or other organic carboxylic acids are used.

The foaming reaction mixture of isocyanate and polyol component are preferably added in polyurethane chemistry conventional catalysts. Examples of such catalysts are: triethylenediamine, N, N-dimethylcyclohexylamine, tetramethylenediamine, 1-methyl-4-dimethylaminoethylpiperazine, triethylamine, tributylamine, dimethylbenzylamine, N, N ', N' '- tris (dimethylaminopropyl) hexahydrotriazine, dimethylaminopropylformamide, N, N, N ', N'-tetramethylethylenediamine, N, N, N', N'-tetramethylbutanediamine, tetramethylhexanediamine, pentamethyldiethylenetriamine, tetramethyldiaminoethylether, dimethylpiperazine, 1,2-dimethylimidazole, 1-azabicyclo [3.3.0] octane, bis (dimethylaminopropyl ) urea N-methylmorpholine, N-ethylmorpholine, N-cyclohexylmorpholine, 2,3-dimethyl-3,4,5,6-tetrahydropyrimidine, triethanolamine, diethanolamine, triisopropanolamine, N-methyldiethanolamine, N-ethyldiethanolamine, dimethylethanolamine, tin ( II) acetate, tin (II) octoate, tin (II) ethylhexoate, tin (II) laurate, dibutyltin diacetate, dibutyltin dilaurate, dibutyltin maleate, dioctyltin diacetate, tris- (N, N-dimethylaminopropyl) -s-hexahydrotriazine , Tetramethylammonium hydroxide, Natr iumacetat, sodium octoate, potassium acetate, potassium octoate, sodium hydroxide or mixtures of these catalysts.

Foam stabilizers are preferably added to the intumescent isocyanate and polyol component reaction mixture. In particular, polyether siloxanes come into question here. These compounds are generally designed so that a copolymer of ethylene oxide and propylene oxide is connected to a Polydimethylsiloxanrest.

An addition of auxiliaries, additives, catalysts, etc. to the foaming reaction mixture can be done before or during the mixing of polyol and isocyanate component, d. H. the additionally used components are added to the polyol or the isocyanate component prior to their introduction into the mixing head, or they are mixed as the third stream in the mixing head with the isocyanate and polyol component.

The cover layers of the sandwich composite elements are made of a rigid or flexible material. As materials for the cover layers, all materials known to those skilled in the art can be used. Preference is given to metals such as steel (galvanized and / or lacquered), aluminum (lacquered and / or anodised), copper, stainless steel or non-metals such as reinforced, unreinforced and / or filled plastics, such as polyvinyl chloride or polyester-based or glass fibers, impregnated cardboard, paper , Wood, bitumen glass fleece and mineral glass fleece. The cover layers can also be coated with a lacquer. Upper and lower cover layers can be made of different materials.

Such composite elements based on - possibly different (rigid or flexible) - cover layers and a core layer preferably made of rigid polyurethane foam are well known in the prior art and are also referred to as metal composite elements or insulation board. Further layers may be provided between the core layer and the cover layers.

Examples of the application of such composite elements with rigid cover layers are flat or lined wall elements and profiled roof elements for industrial halls and cold storage. The composite elements are also used as truck bodies, hall doors and gates as well as in container construction. Insulation boards as well as composite elements with flexible cover layers are used as insulating materials for roofs, exterior walls and as floorboards.

The preparation of these composite elements by a continuous or discontinuous process is basically known from the prior art. In the preferred continuous process control, the composite elements are produced "endlessly" on so-called double conveyor belts in thicknesses of generally about 20 to 240 mm. Thicknesses of less than 20 mm and over 240 mm are also possible. Such a double conveyor belt usually consists of a circumferential upper belt for guiding the upper cover layer, a circumferential lower belt for guiding the lower cover layer, a feed device for the upper cover layer, a feed device for the lower cover layer, a molding section, within which the polyurethane reaction mixture foamed and reacted between the upper cover layer and the lower cover layer, a lengthening device for the composite element produced and a device for applying the intumescent reaction mixture to the lower cover layer. The basic arrangement of the individual elements for a continuous manufacturing process for sandwich composite elements is known from the prior art, as in DE 1 247 612 (B) , in particular column 4 Z. 27 to column 5, Z. 43 and the figures, and DE 1 609 668 (A1) , in particular p. 3, fourth paragraph to p. 5, first paragraph (page number indication taking into account the cover page as page 1), known.

In the context of the present invention, the still liquid reaction mixture is preferably applied to the lower cover layer (substrate) by means of the device according to the invention. Advantageously, the outgoing lines and the casting rakes, if used, are located at a height of 20 to 500 mm above the lower cover layer and are preferably arranged so that the reaction mixture can be applied to the lower cover layer, without leaving unwetted areas between the individual application areas respective casting rakes on the lower surface layer occur. The now slowly foaming reaction mixture is transported on the lower cover layer by means of a lower belt in the molding section, which is spanned by an upper and lower belt. The foaming reaction mixture reaches the upper cover layer and thus bonds the two outer layers together. Within the molding section, with the upper and lower strips defining the thickness of the product to be produced, the foam solidifies and, after passing through the forming section, is cut to length through a cutting device for cutting the composite elements thus produced into desired lengths.

Examples

The following examples describe the use of the device according to the invention in the production of sandwich composite elements consisting of two metallic cover layers and an intermediate rigid polyurethane foam core layer.

To produce the sandwich composite elements, a commercially available, continuously operating double conveyor belt was used in each case. This technology is known per se and, for example, in DE 1 609 668 A1 described. The components were mixed in a high-pressure mixing head, and the resulting reaction mixture was then applied via a distributor head V via six hoses (outgoing lines) to a lower cover layer (= substrate) of galvanized sheet steel, painted on both sides. The upper cover layer was made of the same material. The hoses were placed at regular intervals across the width of the lower deck to ensure uniform engagement EP 1 857 248 A2 on p. 8 in 1 described. The hoses were each between 65 and 75 cm long in the examples (the six hoses used in a specific example each had exactly the same length). The hoses each had a diameter of 8 mm inside and 10 mm outside. The slight differences in the hose length do not affect the validity of the results.

The rigid foams of the metal composite elements were prepared according to the processing recipes described below. Hydroxyl numbers (OH numbers) were determined according to DIN 53240 in the version of December 1971 determined, acid numbers according to DIN EN ISO 2114 in the version of June 2002; the numerical values given are in each case as mg KOH / g. "Parts" means parts by weight.

Foam system A: rigid polyurethane foam

100 parts by weight of polyol formulation with OH number 305 consisting of:
31 parts of flame retardant (trischloroisopropyl phosphate, TCPP); 1.8 parts of water; 1 part silicone-containing stabilizer; 2.5 parts glycerol; 5 parts of a polyether polyol having OH number 470, prepared by reacting ortho-toluenediamine with ethylene oxide and propylene oxide; 7 parts of a polyether polyol having OH number 400, prepared by reaction of glycerol with propylene oxide; 10 parts of a polyester polyol having OH number 370, prepared by reacting phthalic anhydride, adipic acid and soybean oil fatty acid with 1,1,1-tris (hydroxymethyl) propane (TMP); 11 parts of a brominated polyether polyol having OH number 330; 30.7 parts of one Polyesterpolyetherpolyols having OH number 435, prepared by reaction of phthalic anhydride, diethylene glycol, sorbitol and propylene oxide.

2.4 parts by weight activator consisting of:
20 parts Niax A-1 (70% bis (2-dimethylaminoethyl) ether in dipropylene glycol); 8 parts of dimethylcyclohexylamine; 4 parts of pentamethyldiethylenetriamine; 68 parts of a polyether polyol having OH number 440, prepared by reacting a mixture of sucrose and monoethylene glycol with propylene oxide.

2.2 parts by weight activator consisting of:
25 parts of potassium acetate and 75 parts of diethylene glycol.

4.5 parts by weight of n-pentane

135 parts by weight of 44 V 70 L (Desmodur ^® 44 V 70 L, mixture of 4,4'-diphenylmethane diisocyanate (MDI) and higher functional homologues (PMDI) having a viscosity at 25 ° C of ≥ 610 mPa · s to ≤ 750 mPas. The product contains about 34% 2-core MDI, available from Bayer MaterialScience AG)
Key figure (index): 127

Foam system B: PUR / PIR rigid foam

100 parts by weight of polyol formulation with OH number 190 consisting of:
40 parts of polyester polyether polyol having OH number 300, prepared by esterification of phthalic anhydride with diethylene glycol and reaction of the reaction product with ethylene oxide; 16.1 parts of a polyether polyol having OH number 28, prepared by reacting 1,2-propylene glycol with ethylene oxide and propylene oxide; 12.3 parts of a polyether polyol having OH number 380, prepared by reacting a mixture of sucrose, 1,2-propylene glycol and monoethylene glycol with propylene oxide; 25.6 parts of flame retardant (trischloroisopropyl phosphate, TCPP); 0.8 parts of water; 2.6 parts of silicone-containing stabilizer; 2.6 parts of a polyester polyol of phthalic anhydride and diethylene glycol having OH number 795 and acid number 100.

0.8 parts by weight activator consisting of:
50 parts of dimethylcyclohexylamine; 23.5 parts of pentamethyldiethylenetriamine; 26.5 parts of a polyether having OH number 440, prepared by reacting a mixture of sucrose and monoethylene glycol with propylene oxide.

3.0 parts by weight activator consisting of:
25 parts of potassium acetate and 75 parts of diethylene glycol.

2.0 parts by weight of additive consisting of:
10.9 parts by weight of carbon dioxide, 38.9 parts by weight of isopropanolamine and 50.3 parts by weight of monoethylene glycol.
14.5 parts by weight of n-pentane
200 parts by weight 44 V 70 L
Key figure (index): 331

The following Table 1 shows the service life of the tube materials used, wherein the life is understood as the duration between two tube changes during the production of metal-polyurethane rigid foam composite elements. The service life varies depending on the throughput and any production interruptions. Nevertheless, the difference in the service lives in the comparative examples to the inventive examples is clearly pronounced. Table 1: Comparison of foam systems, hose materials and tool life from the examples. example foam system tubing Release agent content (% by mass) Lifetime [h] 1 (comparison) A polyamide 0 7 2 (comparison) A Low-density polyethylene 0 6 3 (comparison) A polytetrafluoroethylene 0 6 4 (comparison) A polyvinylchloride 0 4 5 (comparison) A TPU ^[a] based on polyether polyol (TPU A) 0.10 ^[b] 3 7 (according to the invention) A TPU ^[a] based on polyether polyol (TPU B) 0.40 ^[b] 48 8 (comparison) B polyamide 0 6 9 (comparison) B polyethylene 0 5 10 (comparison) B polyvinyl chloride; 0 7 11 (comparison) B TPU A ^[a] 0.10 ^[b] 4 12 (according to the invention) B TPU B ^[a] 0.40 ^[b] 48

Remarks:

• [a] All thermoplastic polyurethanes (TPUs) are based on polytetrahydrofuran as the polyether component and 4,4'-diphenylmethane diisocyanate as the isocyanate component.
• [b] Ethylene bis-stearylamide was used as release agent.

As can be seen from the table, significantly longer service lives are achieved with the TPU types according to the invention than in the comparative examples.

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• US 4624213 [0003]
• DE 3151511 A1 [0003]
• GB 1197221 [0003]
• EP 1857248 A2 [0010, 0066]
• WO 2008/018787 A1 [0011]
• WO 2008/104492 A2 [0012]
• WO 2009/077490 A2 [0013]
• WO 2010/108615 A1 [0014, 0044]
• EP 0792917 B1 [0025, 0041]
• DE 2418075 A1 [0040]
• DE 1247612 B [0063]
• DE 1609668 A1 [0063, 0066]

Cited non-patent literature

• Rubber Rubber Plastics, Volume 57, No. 4/2004 [0009]
• Polyurethane Handbook, Günter Oertel, Carl-Hanser Verlag, 1985, p. 405 to p. 417 [0022]
• DIN 55672-1 [0035]
• Mihail Ionescu, Chemistry and Technology of Polyols for Polyurethanes, Rapra Technology Limited, 2005, pp. 321-366 and pp. 419-431 [0053]
• Polyurethane Handbook, Günter Oertel, Carl-Hanser Verlag, 1985, Chapter 6.1, p. 270 [0054]
• DIN 53240 [0067]
• DIN EN ISO 2114 [0067]

Claims (11)

Apparatus for applying intumescent reaction mixtures to a substrate, comprising: (a) a mixing head M for mixing the raw materials required to produce a foam, (b) at least one outlet conduit A for the intumescent reaction mixture, characterized in that at least those containing the intumescent reaction mixture in Contacting parts of the outlet line (s) are made of a thermoplastic polyether polyol-based polyurethane, which at least one release agent in a content of 0.30 mass% to 2.0 mass%, based on the total weight of the thermoplastic polyurethane on polyether polyol Basis, contains. The device of claim 1, wherein the device comprises: (aa) a fluidically behind the mixing head lying distributor head V, on the (B) two to ten outlet lines A are attached to the foaming reaction mixture. Apparatus according to claim 2, wherein the outlet pipes A attached to the distributor head V have the same length, the same cross-section and their parts in contact with the intumescent reaction mixture of the same material. Device according to one of claims 1 to 3, wherein each outlet line A flows into a casting bar G, in each case at least comprising two outlet openings for the foaming reaction mixture. The device of any one of claims 1 to 4, wherein the release agent is selected from the group consisting of fatty acid esters, metal soaps of fatty acid esters, fatty acid amides, polyethylene waxes, and mixtures of the foregoing. Device according to one of claims 1 to 5, wherein all parts of the device which come into contact with the intumescent reaction mixture are made of polyether polyol-based thermoplastic polyurethane which contains at least one release agent in a content of 0.3 mass% to 2.0 mass %, based on the total mass of the thermoplastic polyether polyol-based polyurethane. Device according to one of claims 1 to 6, wherein polyether polyol-based thermoplastic polyurethane is obtained by reacting at least one polyether polyol having a molecular weight between 800 g / mol and 5000 g / mol in the presence of at least one diol having a molecular weight below 500 g / mol at least one diisocyanate. The device of claim 7, wherein each polyether polyol used is formed by polymerizing one or more epoxides selected from the group consisting of Ethylene oxide, propylene oxide, butylene oxide, tetrahydrofuran, styrene oxide and epichlorohydrin and wherein each diisocyanate used is selected from the group consisting of Tolylene diisocyanate, diphenylmethane diisocyanate, xylylene diisocyanate, naphthylene diisocyanate, hexamethylene diisocyanate, diisocyanatodicyclohexylmethane and isophorone diisocyanate, and wherein each diol used having a molecular weight below 500 g / mol is selected from the group consisting of Ethylene glycol, diethylene glycol, butanediol, hexanediol, octanediol, decanediol, dodecanediol and hydroquinone bis (2-hydroxyethyl ether). Use of a device according to any one of claims 1 to 8 in the manufacture of composite elements comprising a foam layer on a substrate. Use according to claim 9, wherein the composite element is a sandwich composite element in which the foam layer is disposed between the substrate and an upper cover layer. Use according to one of claims 10 or 11, wherein at least one isocyanate component and at least one polyol component are used as raw materials for the foam layer.