Heated sandwich panel

Abstract

Sandwich panel that can be heated on one or both sides and has the following individual components: - a fiber-reinforced plastic cover layer - a carrier material with integrated resistance heating embedded in a first matrix, optionally with sensors, actuators - a sandwich core, preferably a rigid foam - a second matrix, optionally with a carrier material, optionally with a resistance heater and / or with sensors / actuators - a fiber-reinforced plastic cover layer.

Description

[0001] The present invention relates to a heatable component that can be used for floors or as a wall element or as a cladding element and that comprises or is formed from a sandwich panel that can be heated on one or both sides. The component can preferably be used as a heatable floor element or roof element in vehicles, particularly rail vehicles.

[0002] Floor, wall, and / or cladding elements are used in many industries, including construction, the automotive industry, the rail industry, and even aerospace. The use of these components often saves time, costs, and weight, and the components can be used as floor elements, wall elements, roof elements, or cladding elements. Summary of the invention

[0003] An object of the present invention is therefore to improve the known sandwich panels which can be used, for example, as heatable building elements for floors.

[0004] This task is achieved by a sandwich panel that can be heated on one or both sides according to the independent claim.

[0005] The sandwich panel or sandwich plate according to the invention has, as a whole, several surprising advantages and functions in combination: - mechanical resilience (stiffness and strength) - low weight (application of lightweight construction concepts) - reduced material usage and can be used in a wide variety of materials - Use of sustainable materials, especially renewable raw materials - extensive functional integration can be implemented (Sensors, actuators, antennas, component and environmental monitoring) - simple process, can be automated - fire-retardant - Soundproofing and sound insulation - Resistance to moisture and other environmental conditions - insulating in terms of temperature and electricity - surprisingly long service life

[0006] The special feature of the sandwich panel or sandwich plate according to the invention lies in the combination of the various individual components to form a composite part with the properties mentioned, which cannot be achieved in combination with the plates in the prior art.

[0007] In particular, previous solutions for floor panels in rail vehicles are surpassed by the heatable sandwich panel according to the invention. Furthermore, the basic structure is expandable and can be combined with various fastening systems.

[0008] The sandwich panel according to the invention, also called sandwich panel or composite panel, comprises a fiber-reinforced plastic cover layer, in particular with a fire-retardant function, a carrier material with integrated resistance heating, which is embedded in a first matrix, a rigid foam or a material suitable as a sandwich core (e.g. cork, wood), a second matrix and a fiber-reinforced plastic cover layer, in particular with a fire-retardant function.

[0009] According to the invention, the sandwich panel, in which the top and bottom sides do not need to be fixed, is formed by or flanked by two fiber-reinforced outer plastic layers, preferably with a fire-retardant function. Within the two fiber-reinforced plastic cover layers is the carrier material with an integrated resistance heater embedded in a matrix. Furthermore, a core material, in particular a rigid foam, and another matrix are located within this sandwich panel.

[0010] The plastic cover layer can be thermoplastic or thermosetting.

[0011] In a further aspect, the invention relates to the use of a heating element consisting of a resistance heater and an application-specific circuit with additional functionality, embroidered or sewn onto a carrier material in combination with the properties of a GRP sandwich panel. The functionality can consist, for example, of safety switches, temperature sensors and controls, sensors for pressure or strain, or data storage devices, or the like. The carrier material can be, for example, a fiber or plastic mesh or a nonwoven, a scrim, or a fabric. An exemplary carrier material, without being limited thereto, can be a reinforcing fabric (in particular with 75 g / m 2 , glass fiber fabric white DALSYS) are provided

[0012] Preferably, the heating element is embedded in an application-specific matrix, preferably an adhesive, and positioned as close as possible to the fiber-reinforced plastic cover layer on the inside. Embedded between the sandwich core and the cover layer, the generated heat flow is efficiently transferred to the space to be heated via the heated panel side.

[0013] Surprisingly, the sandwich panel has a very high thermal insulation in non-heated parts of the surface, for example in the edge areas.

[0014] This significantly reduces heat loss via thermal bridges to neighboring elements of the overall system, for example a car body of a rail vehicle.

[0015] The heating element can be flexibly adapted to the desired heating areas without any additional effort, thus enabling additional fastenings and low energy consumption.

[0016] The performance of the sandwich panels can also be adapted to the application requirements over a wide range. The homogeneity of the heat distribution across the surface of the sandwich panel can be specifically controlled by the performance and sealing of the resistance elements. This core combination is, or can be, combined with the properties and functions described above. Since the composite is electrically insulating overall, it partially assumes the insulating properties of comparable heating elements. This combination leads to additional weight savings and material reduction.

[0017] In a further preferred embodiment of the invention, the plastic cover layers are designed to be fire-resistant. The fire-resistant function is preferably introduced into the cover layers by the matrix, i.e., specially designed fire-resistant resin systems or thermoplastics. Special fire retardants are mixed into the matrix. The fibers in the cover layer either do not burn or are protected by the matrix. The matrix:fiber ratio can be adjusted for this purpose.

[0018] In a likewise preferred embodiment, the first and second matrices are formed, in particular, from adhesive. A fast-curing, two-component polyurethane adhesive for bonding sandwich panels and similar structures made of different materials can be used for this purpose, for example SikaForce, in particular SikaForce 712L7.

[0019] The sandwich core is preferably a PET rigid foam. PET foams are thermoplastic structural rigid foam systems with closed cells and are ideally suited to form a rigid foam core in the sandwich panel according to the invention. The optimized damage tolerance of this foam enables use in a wide variety of structural sandwich constructions that can also be used at elevated temperatures. Accordingly, the sandwich panels according to the invention can be used just as well in ship and boat construction as in rail vehicles, with use in rail vehicles being preferred.

[0020] Heated sandwich panels, for example, are typically subjected to high loads in the highly stressed entry areas of rail vehicles, such as those caused by loading and unloading or by passengers entering and exiting the vehicle. This repeatedly leads to damage to the heating elements in state-of-the-art floor panels. Surprisingly, the sandwich panel according to the invention, which can be heated on one or both sides, is very robust and can therefore also be used in highly stressed entry areas and rail vehicles without causing damage to the panel. The carrier material (glass mesh, grid, etc.) in combination with the adhesive matrix makes a significant contribution to this.

[0021] In a further preferred embodiment, the sandwich panel is characterized in that the sandwich core is partially substituted with inserts for fastening, inter alia with tolerance-compensating elements, to the car body or superstructures or substructures.

[0022] In a further preferred embodiment, the sandwich panel is characterized in that the sandwich core is partially supplemented with fastening profiles, including tolerance-compensating elements, for connecting the individual sandwich panels to one another.

[0023] In a further preferred embodiment, the sandwich panel is characterized in that the cover layers are supplemented with further coverings or layers which provide further functionality such as fire protection, sound insulation, prevention of abrasion and environmental influences.

[0024] In a further preferred embodiment, the sandwich panel is characterized in that electrically conductive elements are integrated in the sandwich panel, preferably in the matrices.

[0025] The solution according to the invention particularly meets the properties of a sandwich panel for the floor with regard to static requirements and at the same time functionally integrates the heating unit therein.

[0026] The sandwich panel according to the invention combines high functional density with the lowest possible weight for the respective design case. When appropriate materials and manufacturing processes are used, it is suitable for ensuring long service lives in applications, for example, in rail vehicles.

[0027] The sandwich panel is characterized by the exceptionally high efficiency of its integrated heating elements. This is achieved, among other things, through the targeted use of thermally insulating materials for the cover layers, the matrix, and the sandwich core. These materials prevent heat loss and optimize heat conduction within the panel. The integration of the resistance heating close to the surface ensures that the generated heat is transferred directly and quickly to the desired surface. Furthermore, the electrical insulation of the heating elements is ensured by the use of moisture-resistant materials, which significantly increases the safety and durability of the panel, especially when used in humid or demanding environments such as those found in rail vehicles.

[0028] The sandwich panel offers a lightweight construction that can be tailored to the specific application while simultaneously enabling high functional density. By using fiber-reinforced plastics and lightweight rigid foam as the sandwich core, the weight of the panel can be minimized without compromising structural integrity or heating performance. This property is particularly advantageous in applications such as rail vehicles, where low weight and high functionality play a key role. The combination of lightweight construction and optimized heating technology results in an efficient and cost-effective solution.

[0029] The innovative composite construction of the sandwich panel allows for the integration of a wide range of materials based on the multi-material approach. This versatility in material selection makes it possible to tailor the panel specifically to the specific requirements of the application, be it in terms of mechanical properties, thermal insulation, or electrical insulation. In addition, the panel offers space for the integration of additional functions, such as sensors and actuators, without compromising the overall structure. This system integration promotes synergy between the materials and functions used, thereby achieving highly efficient use of available resources. This leads to optimized performance, which extends the service life of the panel and significantly expands its possible applications in a wide variety of industries, such as the railway industry.

[0030] The selection of high-quality materials and the use of innovative manufacturing processes ensure a long service life of the sandwich panel. Its high resistance to mechanical and thermal stress, combined with its moisture-resistant properties, ensures reliable performance over a long period of time. This durability is a decisive advantage, particularly in demanding environments such as those found in rail vehicles or other modes of transport, as it reduces maintenance costs and minimizes downtime.

[0031] The sandwich panel can be flexibly adapted to different technical requirements and environmental conditions. This is achieved through the modularity of the design, which allows for a targeted selection of materials and functions. With the option to integrate heating elements, sensors, and actuators as needed, as well as the ability to adapt the design to various mechanical and thermal requirements, the sandwich panel is particularly versatile and suitable for a wide range of applications.

[0032] The sandwich panel enables an extremely high functional density that can be flexibly and precisely adapted to the specific requirements of an application. Its modular structure and the ability to integrate various functions offer numerous advantages.

[0033] The sandwich panel can be designed to withstand high mechanical loads and stresses, which is particularly advantageous in demanding applications such as rail transport. Its high strength is achieved through the careful selection of materials and the sandwich construction, which simultaneously minimizes weight.

[0034] The geometry of the sandwich panel can be flexibly adapted to integrate it into various system environments. This enables seamless adaptation to the car body concept of rail vehicles or other complex system architectures.

[0035] The use of appropriate materials in the cover layers and the core achieves increased fire protection, ensuring operational safety and reducing the risk of fire damage.

[0036] Thanks to the careful selection of the sandwich core and fiber-reinforced face layers, the sandwich panel also offers excellent sound insulation. This property is particularly advantageous in vehicles or systems where noise reduction is a key consideration.

[0037] When selecting materials and manufacturing technologies, environmentally friendly and sustainable options can be used, thereby reducing life cycle costs and CO 2 -Footprint of the sandwich panel can be reduced.

[0038] The sandwich panel can be ideally integrated into the car body concept of rail vehicles, enabling seamless system integration.

[0039] It contributes to reducing the overall weight and improving the functionality of the vehicle.

[0040] The use of highly durable materials makes the sandwich panel resistant to various environmental influences, such as moisture, temperature fluctuations, and UV radiation. This contributes to a long service life and low maintenance costs.

[0041] The integrated heating elements offer an efficient heating solution for various applications, such as vehicle air conditioning or heating specific vehicle areas.

[0042] The sandwich panel can be equipped with sensors and actuators that enable intelligent system control and continuous monitoring of operating conditions. This ensures proactive maintenance and optimized operation.

[0043] The ability to integrate electronics into the sandwich panel enables central control and communication within the system, for example in connection with heating systems, sensors or other electrical components.

[0044] The use of special materials makes the sandwich panel electrically and thermally insulating. These properties are particularly important for safety and energy efficiency, for example, when using heating elements.

[0045] Another key advantage of sandwich panels is the reduction in weight while maintaining high strength and functionality. This can be achieved through various approaches. The use of fiber-reinforced plastic composites ensures an optimal combination of low weight and high mechanical strength. These composite materials offer high stability while maintaining low density, which significantly reduces the weight of the sandwich panel. The use of lightweight core materials such as rigid foam in sandwich construction also contributes to weight savings without compromising the mechanical properties of the panel. This results in excellent strength with reduced weight, which is particularly advantageous in the transportation sector. The ability to combine different materials allows the sandwich panel to be tailored to the specific requirements of the respective application.This allows for targeted control of material properties such as strength, damping and insulation, achieving a perfect balance between weight, functionality and performance.

[0046] The lightweight system approach allows the sandwich panel to be integrated into the overall system, thus reducing the weight of the final product. This contributes to improved efficiency and optimized energy consumption, particularly in applications such as rail vehicles, where the overall weight of the vehicle is critical.

[0047] The long service life and low maintenance of the sandwich panel result from the choice of the right materials, manufacturing technologies and system integration.

[0048] The choice of highly durable, long-lasting materials ensures high resistance to mechanical and thermal stress, as well as environmental influences. This extends the service life of the sandwich panel and reduces the need for frequent maintenance.

[0049] The use of advanced manufacturing technologies, such as automated production and precise material selection, further optimizes the quality and durability of the sandwich panel. These technologies enable consistent quality and high manufacturing accuracy.

[0050] The integration of sensors and active monitoring systems into the sandwich panel enables continuous evaluation of its condition. This helps detect signs of wear early and perform targeted maintenance, extending its service life and minimizing maintenance costs.

[0051] Careful design planning and the complete integration of the sandwich panel into the overall system enable optimal use of available resources and maximized service life. This results in a robust and reliable solution that reduces operating and maintenance costs in the long term.

[0052] In a further aspect, the invention relates to a rail vehicle comprising a sandwich panel according to the invention.

[0053] The average person skilled in the art recognizes that technical features, definitions and advantages of the sandwich panel according to the invention and of preferred embodiments of the sandwich panel also apply to the rail vehicle, and vice versa.

Claims

[1] Sandwich panel that can be heated on one or both sides and has the following individual components: - a fiber-reinforced plastic cover layer - a carrier material with integrated resistance heating embedded in a first matrix, optionally with sensors, actuators - a sandwich core, preferably a rigid foam - a second matrix, optionally with a carrier material, optionally with a resistance heater and / or with sensors / actuators - a fiber-reinforced plastic cover layer. [2] Sandwich panel according to claim 1, characterized by that the plastic cover layer is fire-retardant. [3] Sandwich panel according to claim 1 or 2, characterized by that the matrix is ​​an adhesive. [4] Sandwich panel according to one or more of the preceding claims, characterized by that the sandwich core is a rigid foam, preferably a PET rigid foam. [5] Sandwich panel according to one or more of the preceding claims, characterized by that the carrier material is a fiber or plastic net, grid, fleece, scrim and / or fabric. [6] Sandwich panel according to one or more of the preceding claims, characterized by that the sandwich core is partially replaced with inserts for fastening, including tolerance-compensating elements, to the car body or superstructures or substructures. [7] Sandwich panel according to one or more of the preceding claims, characterized by that the sandwich core is partially supplemented with fastening profiles, including tolerance-compensating elements, for connecting the individual sandwich panels to each other. [8] Sandwich panel according to one or more of the preceding claims, characterized bythat the top layers are supplemented with additional coverings or layers which provide additional functionality such as fire protection, sound insulation, prevention of abrasion and environmental influences. [9] Sandwich panel according to one or more of the preceding claims, characterized by that electrically conductive elements are integrated into the sandwich panel, preferably in the matrices. [10] Rail vehicle comprising a sandwich panel according to one of claims 1 to 9.