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TWI628065B - 使用具有外層之可發泡介質的模內發泡方法，及可由其獲得之塑膠模塑物 - Google Patents

使用具有外層之可發泡介質的模內發泡方法，及可由其獲得之塑膠模塑物 Download PDF

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Publication number
TWI628065B
TWI628065B TW100126575A TW100126575A TWI628065B TW I628065 B TWI628065 B TW I628065B TW 100126575 A TW100126575 A TW 100126575A TW 100126575 A TW100126575 A TW 100126575A TW I628065 B TWI628065 B TW I628065B
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TW
Taiwan
Prior art keywords
plastic
plastic foam
outer layer
meth
fiber
Prior art date
Application number
TW100126575A
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English (en)
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TW201221330A (en
Inventor
阿尼 克瑞茲
阿賽爾 日喬尼
亞歷山大 洛斯
瑞納 紀莫曼
Original Assignee
贏創羅恩有限責任公司
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Publication of TW201221330A publication Critical patent/TW201221330A/zh
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Publication of TWI628065B publication Critical patent/TWI628065B/zh

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Abstract

使用固態可發泡塑膠(例如聚(甲基)丙烯醯亞胺(PMI)、聚氯乙烯(PVC)、聚胺基甲酸酯(PU)或聚(甲基)丙烯酸酯(PMMA))可製造本質上均勻之塑膠發泡體複合模塑物，且該模塑物在發泡程序期間在約攝氏200度下形成與一外層或複數個外層或與複數個相同或不同外層之安定機械性接合。

Description

使用具有外層之可發泡介質的模內發泡方法，及可由其獲得之塑膠模塑物
本發明有關製造複合組件之單一階段發泡、積層及模塑方法，該等複合組件係由可發泡介質(例如可發泡塑膠)所製成之發泡體核心與塑膠及/或複合材料及/或金屬所製成之一或多個外層所構成。該塑膠發泡體複合模塑物具有高機械強度及具有比相當之金屬組件低之質量，因此具有用作太空船、飛行器、船舶及陸地交通工具中之組件及用於其他結構元件的優異安定性。
複合材料之發泡程序已為人習知。例如，袋式模塑法(Bladder moulding process)使用由例如聚矽氧橡膠所製成之袋以在模中擴張由複合材料(例如，玻璃纖維強化塑膠或碳纖維強化塑膠)所製成之型坯，並將該型坯成形為該模及獲致該型坯之熱硬化。
袋式模塑法：在袋式模塑法(尤其用於運動製品產業，其實例為腳踏車框架、網球拍等)中，在升高之內部壓力與升高溫度下，利用聚矽氧袋將由纖維強化塑膠(FRP)所製成之外層加壓及硬化。為此，FRP大部分具有熱固性基質(稱之為預浸體)插入模中。為了複製該模之外部形狀，一旦該模封閉，在該模內部將聚矽氧袋加壓。然後在界定溫度下硬化FRP。然後開啟該模，將該組件脫模並移出該聚矽氧袋。若基於與組件相關之因素，不可能修剪該袋，則使用「犧牲核心」。
DE 198 45 269(MBK)描述由氣墊所環繞之袋通過複製形狀之模穴然後擴張，因此完全填滿該模穴之方式。
DE 10 2007 056 830(Head)描述製造由複合材料所製成之網球拍的袋式模塑法。
發明DE 10 2007 051 517(TU Dresden)有關空心軸，或者分別有關用於與功能元件互鎖的由纖維複合材料所製成之空心軸。空心軸之套管中具有至少兩個纖維層，該等層中之纖維取向不同，且具有圓形邊緣輪廓。該等功能元件具有對應於該軸輪廓的輪廓接觸區，且該等功能元件具有功能區配置，過渡元件位於該輪廓接觸區與功能區配置之間。根據該發明之軸以及功能元件具有輕重量。
DE 10 2004 015 072(Rhm GmbH & Co. KG)描述製造藉由擠製塑膠模塑組成物由透明塑膠所製成之棒的方法，其特徵在於將經擠製之塑膠模塑組成物分成兩個不同條，且使用塑膠模塑組成物1擠製塑膠管，然後進入真空槽校正器約20 cm之後，與先前隔離之熔融塑膠模塑組成物2並行地接收新擠製之管，並如慣用管擠製般進一步處理該新形成的塑膠模塑物。
DE 102 40 395(Lisa Drxlmaier GmbH)描述欲用於機動交通工具且迄今係藉由內部高壓法從鋼管製造的橫向構件；可將各種接收其他部件的構件焊接於該橫向構件。本發明之橫向構件包含由纖維複合材料或金屬-塑膠混合設計所製成之曲管，已於其上射出接收其他部件的各種構件。
DE 10 2009 002 232(Volkswagen AG)描述製造凸輪軸的方法及設備，其中該方法比先前方法(例如內部高壓形成法(IHU)或澆鑄法)更具彈性，且產物具有較輕重量。該凸輪軸係由纖維強化塑膠所組成，且該製造程序係由以下步驟構成：
‧　將預製負載導入元件配置在具有空心結構的半成品纖維產品上，
‧　將彈性空心體導入該半成品纖維產品，及
‧　將整體配置置於可控制溫度之模，
‧　將該等負載導入元件定位在該模中，
‧　填滿該彈性空心體，如此迫使該半成品成為該模之形狀以及該負載導入元件之形狀，
‧　插入基質材料並熱固化，
‧　該軸可於固化後脫模。
DE 10 2007 026 553(TU Dresden)描述具有汽車車輪輪廓的多室複合結構以用作軸線與軸，例如用於飛行器起落架。該組件之高機械強度係經由不同角度之纖維層的配置來獲致。
DE 10 2005 020 274(Denk Engineering GmbH)描述製造纖維強化塑膠模塑部件的方法，其係藉由將纖維積層物施加於可擴張內模塑部件，將該覆蓋纖維積層物的內模塑部件導入陰模並擴張該模塑部件，其中該內模塑部件擴張並將纖維材料迫使該組件模的內壁上。可將金屬部件或事先硬化之纖維強化部件導入組件模，在該纖維強化材料硬化後，該等部件已牢固地接合於塑膠模塑部件並提供其額化強化。該核心覆層之擴張係經由導入氣體或液體而發生，但亦可經由低大氣壓力而發生。
DE 10 2005 020 907 A1(TU Dresden)描述由纖維強化塑膠所製成之空心結構，其具有已模塑於該空心結構內部形狀的負載導入元件。該空心結構係由以反應性樹脂混合物飽和之紡織品半成品所構成。該反應性樹脂可人工施加或利用習知注入法(例如樹脂轉送模製(RTM))來施加。使用袋來獲致精確形狀複製。
使用PU之「模內發泡」之顯著特徵本質上：
-　在「標準」PU模塑中，在組件內發生發泡(該方法與構造發泡體方法相似)。
-　使用PU產生「犧牲核心」，然後以外層覆蓋該等犧牲核心。然後該方法包括複數個步驟。
-　在PU之例中，發泡係從液相發生。
為了散逸機動交通工具撞擊的能量，將撞擊元件插入汽車結構內。該等撞擊元件通常係由發泡法從金屬所製造，當發生負載時，其藉由該金屬結構的經界定變形(崩陷)來散逸能量。
個別特定應用(非常少量製造的賽車或跑車)已使用具有發泡體核心與FRP外層的撞擊元件。然而，該製造法與根據本發明之製造程序本質上不同：纖維係在第二程序步驟中施加於置於模中的發泡體核心，然後使用第三步驟加固該等纖維。
PU發泡體係例如用於交通工具體加工以獲致加勁效果(包括在撞擊時易受應力的位置)。該等發泡體係直接注入中空金屬輪廓，並於導入程序期間擴張(例如擴張成汽車之B柱(B-column))。此處之程序使用PU原位發泡的可能性。
因此本發明目的係：
‧　發展原位發泡法，
‧　發展製造包含發泡體(塑膠發泡體複合模塑物)之立體組件的簡單單一階段方法，
‧　發展製造包含發泡體(塑膠發泡體複合模塑物)且已由一及/或多個外層包覆的簡單單一階段方法，其中該外層可彼此接合，
‧　製造由塑膠發泡體複合模塑物所製成之輕量結構撞擊元件，
‧　製造具有發泡體核心與外層或複數個外層之模塑物與輪廓結構，
‧　製造板狀塑膠發泡體複合模塑物，
‧　製造強力導入結構(插入件)或接合結構或加勁結構的一體成型組件，
‧　原位製造發泡體箔，
‧　感測器，
‧　製造具有可變/可調整密度之組件，
‧　天線(間隔件)，
‧　製造用於提高抗壓性與抗屈曲性之元件，
‧　製造實質上非常均勻之發泡體結構，
‧　製造具有各向異性機械性質的組件，
‧　經由塑膠發泡體複合模塑物加勁縱向與橫向構件(例如汽車中之A柱、B柱及C柱)。
目的之獲致
本發明目的係經由塑膠發泡體複合模塑物與經由製造彼之方法而獲致：
使用固態可發泡塑膠(諸如聚(甲基)丙烯醯亞胺(PMI)、聚氯乙烯(PVC)、聚胺基甲酸酯(PU)或聚(甲基)丙烯酸酯(PMMA))可製造本質上均勻之塑膠發泡體複合模塑物，且該模塑物在發泡程序期間中形成與一外層或與複數個相同或不同外層之安定機械性接合。
下文之「安定機械性」意指脫離該外層所需的力(測試方法：根據DIN 53295之桶剝離測試)大於該材料之典型剝離力。就ROHACELL而言，該等剝離力在10至80 Nmm/mm範圍中。
外層
塑膠發泡體複合模塑物的外層可例如由下列者所組成：
-　具有或不具強化材料之熱塑性材料，其實例為各種聚醯胺(PA、PA 66、PA 12)、聚丙烯(PP)、聚對苯二甲酸丁二酯(PBT)、聚醚醚酮(PEEK)，其隨意地具有藉由例如玻璃纖維、聚芳醯胺纖維、聚合物纖維、天然纖維或碳纖維強化，其實例為PA 6 GF
-　熱塑性纖維複合材料或有機板，例如連續纖維強化PA 6
-　具有或不具強化材料之熱固性材料，其實例為預浸體
-　僅有強化材料，其實例為由玻璃、碳、聚芳醯胺、聚合物所製成之纖維，例如玄武岩纖維、硼纖維、陶瓷纖維、金屬纖維、聚酯纖維、耐綸纖維、聚乙烯纖維、Plexiglas纖維、天然纖維，諸如羊毛纖維、撓性纖維、大麻纖維、瓊麻纖維
-　金屬，其實例為鋁、高強度鋼或其他鋼
-　彈性體，諸如橡膠、PU、纖維強化橡膠或纖維強化PU
-　凝膠塗層
-　及由一或多種上述材料所製成之組合物，其實例為由鋪設之玻璃纖維紗及鋪設之碳纖維紗之組合物所製成的多層結構(積層物)。
可用於塑膠發泡體複合模塑物之外層的強化材料係塑膠技術中的慣用纖維材料，其實例為：
-　玻璃纖維，例如呈短玻璃纖維、長玻璃纖維、連續長絲纖維、鋪設纖維之紗、編織纖維、針織物、非織物或墊
-　碳纖維，例如呈短玻璃纖維、長玻璃纖維、連續長絲纖維、鋪設纖維之紗、編織纖維、針織物、非織物或墊
-　聚芳醯胺纖維，例如呈短玻璃纖維、長玻璃纖維、連續長絲纖維、鋪設纖維之紗、編織纖維、針織物、非織物或墊
-　天然纖維，其實例為羊毛纖維、撓性纖維、大麻纖維、瓊麻纖維
-　合成纖維，其實例為聚酯纖維、耐綸纖維、聚乙烯纖維、Plexiglas纖維
-　玻璃微珠，其實例為玻璃微珠強化之聚醯胺(例如PA 6 GR30)
該外層亦可以黏著劑彼此接合。
聚(甲基)丙烯醯亞胺與聚(甲基)丙烯醯亞胺發泡體
與本發明方法特別相關之核心層包含聚(甲基)丙烯醯亞胺發泡體。
括號之詞意在表示隨意的特徵。因此，例如(甲基)丙烯酸不只意指丙烯酸化合物，但亦指甲基丙烯酸化合物以及此二者的混合物。
可從本發明之組成物獲得之聚(甲基)丙烯醯亞胺發泡體具有經由式(I)所表示的重複單元，
其中
R1與R2係相同或不同，其為氫或甲基，且R3為氫或具有至多達20個碳原子的烷基或芳基。
較佳係結構(I)之單元形成該聚(甲基)丙烯醯亞胺發泡體的多於30重量%以上，特別是多於50重量%且最特別係多於80重量%。
剛性聚(甲基)丙烯醯亞胺發泡體的製造本身為人習知係例如描述於GB專利1 078 425、GB專利1 045 229、DE專利1 817 156(=美國專利3 627 711)或DE專利27 26 259(=美國專利4 139 685)或DE 199 17 987。
例如，結構式(I)之單元經由加熱至150℃至250℃時環化異構反應而尤其形成(甲基)丙烯酸之相鄰單元及(甲基)丙烯腈之相鄰單元(參考DE-C 18 17 156、DE-C 27 26 259、EP-B 146 892)。在一般方法中，先在自由基起始劑之存在並於低溫(例如30℃至60℃)下然後加熱至60℃至120℃，經由單體之聚合作用製造前驅物，接著藉由存在之發泡劑經由加熱至約180℃至250℃發泡(詳見EP-B 356 714)。
為此，例如可先形成共聚物，其包含(甲基)丙烯酸與(甲基)丙烯腈，此二者之莫耳比較佳為1：3至3：1。
該共聚物可另外包含例如從丙烯酸或甲基丙烯酸與特別是具有1至4個碳原子之低碳醇之酯，或從苯乙烯、從順丁烯二酸或其酐、從伊康酸或其酐、從乙烯吡咯啶酮、從氯乙烯或從偏二氯乙烯所衍生之其他單體單元。無法環化或極難以環化之共聚單體的比例不應超過以單體重量計之下列值：30重量%，較佳為20重量%，特佳為10重量%。
可以同樣習知方式使用之具有優點的其他單體為少量交聯劑，例如丙烯酸烯丙酯、甲基丙烯酸烯丙酯、二丙烯酸乙二醇酯或二甲基丙烯酸乙二醇酯，或丙烯酸或甲基丙烯酸之多價金屬鹽，例如甲基丙烯酸鎂。該交聯劑之定量比例以可聚合單體之總量計經常在0.005重量%至5重量%範圍中。
此外可能使用金屬鹽加成作用，其中該等金屬鹽時常用以減少煙量。其中，尤其是鹼金屬或鹼土金屬或鋅、鋯或鉛的丙烯酸鹽或甲基丙烯酸鹽。
較佳者為Na、K、Zn及Ca之(甲基)丙烯酸鹽。2至5重量份之單體量顯著降低根據FAR 25.853a燃燒試驗中的煙密度。
聚合起始劑
所使用之聚合起始劑包含本身係(甲基)丙烯酸酯之聚合的慣用聚合起始劑，其實例為偶氮化合物，諸如偶氮二異丁腈，以及過氧化物，諸如過氧化二苯甲醯或過氧化二月桂醯基，以及其他過氧化物化合物，諸如過辛酸三級丁酯(tert-butyl peroctanoate)，或過縮酮(perketal)，以及隨意的氧化還原起始劑(本方面茲參考例如H. Rauch-Puntigam,Th. Vlker,Acryl- und Methacrylverbindungen[Acrylic and methacrylic compounds],Springer,Heidelberg,1967，或Kirk-Othmer,Encyclopedia of Chemical Technology，第1卷，第286頁以下，John Wiley & Sons,New York,1978)。聚合起始劑之較佳用量以起始材料計為0.01至0.3重量%。
亦可能有利的是結合聚合起始劑與關於時間與溫度的不同分解性質。非常適合之方法的實例係同時使用過特戊酸三級丁酯、過苯甲酸三級丁酯與2-乙基過己酸三級丁酯，或同時使用過苯甲酸三級丁酯、2,2-偶氮雙異-2,4-二甲基戊腈、2,2-偶氮雙異丁腈及過氧化二(三級丁基)。
調節劑
經由在分子量調節劑之存在下聚合單體混合物來調整共聚物之分子量，特別實例係就本方法而言習知之硫醇，例如正丁硫醇、正十二硫醇、2-巰乙醇或巰乙酸2-乙基己酯，或其他醌或萜烯，其中該等分子量調節劑之一般用量以單體混合物計為0.01重量%至5重量%，較佳為0.1重量%至2重量%，特佳係以單體混合物計為0.2重量%至1重量%(參考例如H. Rauch-Puntigam,Th. Vlker,"Acryl- und Methacrylverbindungen"[Acrylic and methacrylic compounds],Springer,Heidelberg,1967；Houben-Weyl,Methoden der organischen Chemie[Methods of organic chemistry]，第XIV/1卷，第66頁，Georg Thieme,Heidelberg,1961或Kirk-Othmer,Encyclopedia of Chemical Technology，第1卷，第296頁以下，J. Wiley,New York,1978)。
聚合方法較佳使用整體聚合法之變體，例如習知為細胞法(cell process)，但不侷限於此。
該等聚合物之重量平均莫耳質量較佳大於106 g/mol，特別是大於3×106 g/mol，但無意侷限於由此產生之限制。
轉換成含有醯亞胺基之聚合物期間的共聚物之發泡係以習知方式藉由使用發泡劑獲致，其中該等發泡劑在150℃至250℃下經由分解與汽化而形成氣相。具有醯胺結構之發泡劑(例如脲、一甲脲或N,N'-二甲脲、甲醯胺或一甲基甲醯胺)分解並伴隨釋放氨或胺，此有助於額外形成醯亞胺基。然而，亦可能使用無氮發泡劑，諸如甲酸、水或具有3至8個碳原子之一元脂族醇，諸如1-丙醇、2-丙醇、正丁-1-醇、正丁-2-醇、異丁-1-醇、異丁-2-醇、戊醇及/或己醇。
發泡劑之用量取決於所需之發泡體密度，但在本文之反應混合物中該等發泡劑的一般量以所使用單體計為約0.5重量%至15重量%。
前驅物可此外包含慣用添加劑。其中尤其是抗靜電劑、抗氧化劑、脫模劑、潤滑劑、染料、滯焰劑、流動性改良劑、填料、光安定劑及有機磷化合物，諸如亞磷酸鹽或膦酸鹽、顏料、耐候安定劑及塑化劑。
較佳添加劑之其他類別係傳導性粒子，其中該等傳導性粒子抑制發泡體靜電充電。該等傳導性粒子中尤其特別的是金屬粒子與碳黑粒子，彼等分別亦可呈纖維形式，大小在10 nm至10 mm之範圍中，如EP 0 356 714 A1所述。
可使用之特佳聚(甲基)丙烯醯亞胺發泡體之一係例如經由以下步驟獲得：
1.　經由自由基共聚由以下者所組成之組成物來製造共聚物片：
(a)　20重量%至60重量%之甲基丙烯腈、80重量%至40重量%之甲基丙烯酸及隨意的以整體甲基丙烯酸與甲基丙烯腈計至高達20重量%之其他單官能基乙烯式不飽和單體所製成之單體混合物
(b)　0.5重量%至15重量%之由甲醯胺或一甲基甲醯胺與分子中具有3至8個碳原子之一元脂族醇所製成之發泡劑混合物
(c)　交聯劑系統，其係由以下者組成
(c.1)　0.005重量%至5重量%之進行自由基聚合且分子中具有至少兩個雙鍵之乙烯式不飽和化合物，及
(c.2)　1重量%至5重量%之氧化鎂或氧化鋅，其溶解於該單體混合物
(d)　起始劑系統
(e)　慣用添加劑
(f)　調節劑或調節劑混合物。
2.該混合物係在30℃至45℃下於兩片大小為50*50 cm之玻璃片所形成且離邊緣密封厚度2.2 cm之腔室中聚合數天。然後對該共聚物進行從40℃至130℃為時約20小時之熱調節計畫或最終聚(甲基)丙烯醯亞胺共聚作用。
後續發泡在發生170℃至250℃，較佳為在200℃至250℃且特佳為在220℃至250℃下發生數小時期間。
具有高耐熱性之聚(甲基)丙烯醯亞胺可另外經由聚(甲基)丙烯酸甲酯或其共聚物與一級胺之反應獲得，其同樣可根據本發明使用。可提出下列者作為該同型聚合物亞胺化法之大量實例的代表：US 4 246 374、EP 216 505 A2、EP 860 821。此處之高耐熱性可經由使用芳胺(JP 05222119 A2)或經由使用特定共聚單體(EP 561 230 A2、EP 577 002 A1)來獲致。此處，所有該等反應提供實心聚合物而非發泡體，以及獲得必須在分開之第二步驟中發泡的發泡體。再次，有許多熟悉本技術之人士所習知針對此目的之技術。
剛性共聚(甲基)丙烯醯亞胺發泡體亦可商業獲得，實例為得自Evonik Rhm GmbH之Rohacell，其可以各種密度與大小供應。
該共聚(甲基)丙烯醯亞胺發泡體之密度較佳在20 kg/m3至320 kg/m3之範圍中，特佳在50 kg/m3至110 kg/m3之範圍中。
無意侷限於由此產生之限制，核心層之厚度在1 mm至1 000 mm之範圍中，特別是在5 mm至500 mm之範圍中，最佳係在10 mm至200 mm之範圍中。
該核心層內部亦可具有其他層。然而，藉由本發明方法接合的材料明確地為共聚(甲基)丙烯醯亞胺發泡體及/或外層(見前文)。然而，本發明方法之特定具體實例使用由共聚(甲基)丙烯醯亞胺發泡體所組成之核心層。
亦可能使用聚(甲基)丙烯酸酯作為待發泡之塑膠。
製造程序
該等塑膠發泡體複合產物的製造程序由以下步驟構成：
1.　塑膠模塑物之製造。塑膠模塑物係未經發泡模塑物且係藉由機械方法轉變成所需尺寸。該等尺寸取決於待設定之最終塑膠發泡體複合產物的發泡體密度。有鑑於共聚物之已知密度，因同向性發泡行為，故而根據標的密度，產生恆定發泡因數。該因數可用以計算所需共聚物之尺寸。
2.　將外層置於該模，並可在模與外層之間選擇性施加脫離構件，以促進塑膠發泡體複合產物脫模。
3.　所形成之發泡體的發泡及與外層之接合係在攝氏170度至250度，較佳為200℃至250℃，且特佳為220℃至250℃之溫度的步驟中進行。
該發泡時間係從半小時至五小時，較佳為一個半小時至四個小時，且特佳為兩個小時至三個小時。
4.　冷卻之後，可從該模移出塑膠發泡體複合產物。
對於製造該模之材料有所限制，即其必須能承受該發泡程序的溫度。若該模內側平滑則較為有利於促進塑膠發泡體複合模塑物脫模及獲致該塑膠發泡體複合模塑物的平滑表面。
在可根據本發明方法獲得之塑膠發泡體複合模塑物的重量輕與其優異機械性質的基礎上，該等塑膠發泡體複合模塑物適於用作太空船、飛行器、船舶及陸地交通工具中之組件，以及特別是用作以意外事件中吸收能量之方式變形的組件(撞擊元件)。
實施例
實施例1
根據塑膠模塑物DE 199 17 987 A1之實施例1之規格製造塑膠模塑物。
將約61份之甲基丙烯酸、約39份之甲基丙烯腈、約4.7份之甲醯胺與4.2份之丙-2-醇(異丙醇)與0.3份之異丁酸三級丁酯、0.04份之2-乙基己酸三級丁酯、0.07份之過苯甲酸三級丁酯與0.077份之過新癸酸異丙苯所製成之起始劑混合物所製成的混合物與0.001份之鏈轉移劑在兩片間隔23 mm並藉由周圍封口焊珠所密封之玻璃片之間於攝氏38度之水浴溫度下聚合約66小時，隨後在烘箱中於攝氏115度下後聚合24小時。此提供均勻塑膠模塑物。(上述實例中之「份」始終意指重量份。)
實施例2
將聚醯胺箔(有機板：由Bond Laminates GmbH,Brilon所生產，TEPEX dynalite 102-RG600(1)/47%，0.50 mm黑色(PA6+GF))以接觸該模內緣之方式置於直徑53.5 mm且長265 mm之圓柱形模內部。將根據實施例1所組成且測得為98×17.5×17.5 mm之聚(甲基)丙烯醯亞胺聚合物置於該模中，並將該模加熱至攝氏220度歷時約2小時期間。
冷卻對於塑膠發泡體複合模塑物提供以下機械性質：
-　該組件之密度可調整為10 kg/m3至300 kg/m3之範圍中，但較佳係在50 kg/m3至200 kg/m3之範圍中。
-　遍及整體組件核心，存在相對(需要更多解釋之詞)均勻(即閉孔式)但無明顯偏好方向的發泡體結構。
-　該組件之核心的特徵在於均勻孔室大小分布(該孔室大小在0.05至0.8 mm範圍中，較佳係在0.2至0.6 mm範圍中，視所需之標的密度而定)。
-　發泡體核心之結構幾乎為100%閉孔。
-　與外層之偶合/黏著非常良好。下文之「偶合/黏著非常良好」意指脫離該外層所需的力(測試方法與標準：根據DIN 53295之桶剝離測試)大於該材料之典型剝離力。就ROHACELL而言，該等剝離力在10至80 Nmm/mm範圍中。
-　該程序獲致非常良好之成形。可複製非常小半徑之立體幾何形狀。
-　立體幾何形狀之複製極良好。此意指該程序獲致發泡體核心與外層之高形成度。
-　複合模塑物具有平滑外皮。
-　該塑膠複合模塑物具有非常良好之纖維加固作用。將高溫(見上述範圍)導入該組件以引發發泡程序。此導致材料熔融，例如在外層之熱塑性基質系統之情況下(實例為有機板)。發泡程序另外施加高溫於外層。此形成存在之纖維的良好加固作用。
-　該複合物容許吸收大量能量。吸收大量能量不僅是纖維強化外層之結果，亦為發泡體核心之結果：在曝露於大量能量(例如撞擊)之事件中，一旦強度值超過，則在外層中形成龜裂。此等龜裂從纖維「遷移」至纖維，因此「消耗」能量。該發泡體之狀態如下：當強度值超過時，最前幾個孔室發生稱之為崩陷的程序。然後孔室之完整平面崩陷，然後是接下來之孔室，再來是更接下來之孔室等。如此藉著重複「遭遇障礙(孔室之完整平面)」來散逸能量。
-　該塑膠複合模塑物具有高撓曲與抗扭勁度值、高屈曲應力，及非常良好之屈曲表現。良好之機械性質本質上係從夾層構造原理導出。夾層構造係一種半成品構造，其中複數個具有不同性質之層係埋在一材料中。經常與纖維複合材料結合，諸如纖維-塑膠複合物。夾層構造係組件為藉由相對輕量之核心材料分開的吸收力量之外層所構成的結構。該等部件對於彎曲與屈曲具有非常高之抗性，並具有輕重量。使用線性夾層理論用於相關計算。該核心材料可由紙蜂巢結構、發泡體(剛性發泡體)或巴沙木(balsa wood)所組成。
-　由於例如當發生「彎曲」載重時，尤其是吸收張力與壓縮力之外層發生「彎曲」載重時，所使用之核心片可由較輕重量材料構成，其僅供傳輸剪力。
實施例3
將聚醯胺箔(有機板：由Bond Laminates TEPEX dynalite 102-RG600(1)/47%，0.50 mm黑色(PA6+GF))以接觸該模內緣之方式置於直徑53.5 mm且長265 mm之圓柱形模內部。將根據實施例1所構成的聚(甲基)丙烯醯亞胺聚合物置於該模中。亦將尺寸為12×12 mm(正方形)且長245 mm之鋼條置於該模中，使得該聚醯胺箔不包覆該鋼條，並將該模加熱至約攝氏220度約2小時。
冷卻之後，獲得具有12×12 mm深度之溝槽之塑膠發泡體複合模塑物，其具有下列機械性質：
-　該組件之密度可調整為10 kg/m3至300 kg/m3之範圍中，但較佳係在50 kg/m3至200 kg/m3之範圍中。
-　遍及整體組件核心，存在相對均勻(即閉孔式)但無明顯偏好方向的發泡體結構。
-　該組件之核心的特徵在於均勻孔室大小分布(該孔室大小在0.05至0.8 mm範圍中，較佳係在0.2至0.6 mm範圍中，視所需之標的密度而定)。
-　發泡體核心之結構幾乎為100%閉孔。
-　與外層之偶合/黏著非常良好。下文之「偶合/黏著非常良好」意指脫離該外層所需的力(測試方法與標準：根據DIN 53295之桶剝離測試)大於該材料之典型剝離力。就ROHACELL而言，該等剝離力在10至80 Nmm/mm範圍中。
-　該程序獲致非常良好之成形。可複製非常小半徑之立體幾何形狀。非常良好地複製該鋼條之形狀。
-　立體幾何形狀之複製極良好。此意指該程序獲致發泡體核心與外層之高形成度。
-　複合模塑物具有平滑外皮。
-　該塑膠複合模塑物具有非常良好之纖維加固作用。將高溫(見上述範圍)導入該組件以引發發泡程序。此導致材料熔融，例如在外層之熱塑性基質系統之情況下(實例為有機板)。發泡程序另外施加高壓於外層。此形成存在之纖維的良好加固作用。
-　該複合物容許吸收大量能量。吸收大量能量不僅是纖維強化外層之結果，亦為發泡體核心之結果：在曝露於大量能量(例如撞擊)之事件中，一旦強度值超過，則在外層中形成龜裂。此等龜裂從纖維「遷移」至纖維，因此「消耗」能量。該發泡體之狀態如下：
當強度值超過時，最前幾個孔室發生稱之為崩陷的程序。然後孔室之完整平面崩陷，然後是接下來之孔室，再來是更接下來之孔室等。如此藉著重複「遭遇障礙(孔室之完整平面)」來散逸能量。
-　該塑膠複合模塑物具有高撓曲與抗扭勁度值、高屈曲應力，及非常良好之屈曲表現。良好之機械性質本質上係從夾層構造原理導出。夾層構造係一種半成品構造，其中複數個具有不同性質之層係埋在一材料中。經常與纖維複合材料結合，諸如纖維-塑膠複合物。夾層構造係組件為藉由相對輕量之核心材料分開的吸收力量之外層所構成的結構。該等部件對於彎曲與屈曲具有非常高之抗性，並具有輕重量。使用線性夾層理論用於相關計算。該核心材料可由紙蜂巢結構、發泡體(剛性發泡體)或巴沙木(balsa wood)所組成。由於例如當發生「彎曲」載重時，尤其是吸收張力與壓縮力之外層發生「彎曲」載重時，所使用之核心片可由較輕重量材料構成，其僅供傳輸剪力。

Claims (7)

  1. 一種製造塑膠發泡體複合模塑物之方法，其特徵在於將由熱塑性材料、熱塑性纖維複合材料、有機板(organopanel)及/或金屬組成之一或多個外層及固態未經發泡之聚(甲基)丙烯醯亞胺(P(M)I)共聚物導入模內，然後將該聚(甲基)丙烯醯亞胺發泡而接合於該(等)外層，其中塑膠發泡體複合模塑物係在單一處理步驟中製造。
  2. 如申請專利範圍第1項之方法，其中該發泡係在攝氏170度至攝氏250度下進行。
  3. 一種塑膠發泡體複合模塑物，其可依申請專利範圍第1至2項中之方法獲得。
  4. 如申請專利範圍第3項之塑膠發泡體複合模塑物，其中該塑膠發泡體複合模塑物包含P(M)I發泡體核心及外層，該外層包含熱塑性材料、熱塑性纖維組成物及/或金屬。
  5. 一種如申請專利範圍第3項之塑膠發泡體複合模塑物的用途，其係用作太空船、飛行器、船舶及陸地交通工具中之組件。
  6. 一種如申請專利範圍第3項之塑膠發泡體複合模塑物的用途，其係用作太空船、飛行器、船舶及陸地交通工具中之能量吸收組件。
  7. 一種如申請專利範圍第3項之塑膠發泡體複合模塑物的用途，其係用作太空船、飛行器、船舶及陸地交通工具中之安定化組件。
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