Method for producing a flame-retardant container, flame-retardant container, and system having a flame-retardant container

Abstract

The invention relates to a method for producing a flame-retardant container (100), comprising a treatment step and an application step. In the treatment step, at least one surface of a blank container (110) made of plastic, in particular of thermoplastic, is treated in order to produce a treated surface (115) of the blank container (110). In the application step, a flame-retardant coating (120) is applied to the treated surface (115) in order to produce the flame-retardant container (100).

Description

[0001] DESCRIPTION

[0002] Method for producing a fire-retardant container, fire-retardant container and system comprising a fire-retardant container

[0003] The present approach relates to a method for producing a fire-retardant container, for example for a rail vehicle, to a fire-retardant container and to a system comprising a fire-retardant container, for example a windscreen washer system for a rail vehicle.

[0004] Current flame-retardant plastic containers only meet stringent fire protection standards. The washer fluid containers currently used for windshield washer systems on rail vehicles, if made of plastic, are made of a material that is no longer approved. Therefore, a welded metal construction is currently primarily used as an alternative.

[0005] Against this background, the object of the present approach is to create an improved method for producing a fire-retardant container, an improved fire-retardant container and an improved system with a fire-retardant container.

[0006] This object is achieved by a method for producing a fire-retardant container, a fire-retardant container and an improved system with a fire-retardant container having the steps or features of the independent claims.

[0007] The advantages achievable with the presented approach are that an improved fire-resistant plastic container can be produced quickly and easily.

[0008] A method for producing a fire-retardant container comprises a carrying out step and an application step. In the carrying out step, a surface treatment is carried out on at least one surface of a raw container made of plastic, in particular a thermoplastic or a thermoset, to produce a treated surface of the raw container. In the application step, a fire-retardant coating is applied to the treated surface to produce the fire-retardant container.

[0009] The fire-retardant container can be used, for example, in vehicles, such as rail vehicles or trucks, or in buildings. The fire-retardant container, i.e., a container with fire protection, can be, for example, a plastic washer fluid tank for a windshield washer system for a rail vehicle. The raw container can be tank- or canister-shaped and, for example, with a volume of at least 3 dm 3 , at least 5 dm 3 , at least 10 dm 3 , at least 1 sqm 3 or at least 10 sqm 3be formed. In the carrying out step, a roughening of at least the surface of the raw container can be carried out during the surface treatment in order to create a roughened surface of the raw container. Additionally or alternatively, chemically polar structures can be created on the surface during the surface treatment, for example by plasma or corona treatment or similar processes. Alternatively or in addition to a physical surface treatment, such as a plasma or corona treatment, at least one chemical surface treatment can also be carried out, for example using oxidative chemicals. The surface treatment can serve to improve the bonding of the fire-retardant coating applied in the following step to the surface. In the carrying out step, the surface treatment can be carried out on several surfaces of the raw container.For example, in the step of performing the surface treatment can also be carried out on the entire outer surface and / or inner surface of the raw container.

[0010] The method may further comprise a production step in which the raw container is produced using a plastic material. The plastic material may, for example, comprise polyethylene. Such plastic containers can be produced quickly, easily, and inexpensively. According to one embodiment, in the surface treatment step, an activation of at least one surface of the raw container may be performed to produce the treated surface of the raw container.

[0011] According to one embodiment, the surface treatment step can involve flame treatment of at least the surface of the raw container to create the treated surface of the raw container. Such flame treatment serves to increase the surface tension of the surface, i.e., to activate the surface. This may also result in improved bondability of the surface. This ensures suitable adhesion of the fire-retardant coating to the raw material. For example, a propane or acetylene flame with excess oxygen can be used for the flame treatment.

[0012] According to one embodiment, in the step of carrying out the surface treatment, a chemical treatment, in particular with a primer, can be carried out on at least the surface of the raw container in order to produce the treated surface of the raw container.

[0013] According to one embodiment, in the step of carrying out the surface treatment, a mechanical treatment, in particular by sandblasting, of at least the surface of the raw container can be carried out in order to produce the treated surface of the raw container.

[0014] According to one embodiment, the raw container can be produced in the production step using an injection molding process. The injection molding process can be a special injection molding process, e.g., rotational molding, for example a so-called "rotomold," or rotary air jetting or rotary blow molding, for example a so-called "blow mold," including plastic sheet material welded to form a container, all possible manufacturing methods, as well as the combination of several processes, for the production of plastic containers (tanks, canisters). In this way, a raw container made of, for example, thermoplastic, can be created quickly and easily. The fire-retardant coating can be based on a 1-component system or a 2-component system, for example, a resin and hardener component.Thus, during the application step, a one-component or two-component polyurethane-based compound can be applied to the treated surface as the fire-retardant coating. This can, for example, be an intumescent two-component polyurethane-based compound. Such a material is characterized by high resistance to climatic and mechanical influences.

[0015] For example, in the application step, the fire-retardant coating comprising resin and / or a hardener may be applied to the treated surface. A mixing ratio in weight percent may, for example, be 100 parts resin to

[0016] 12.5 parts hardener. A mixing ratio in volume % can be 100 parts resin to

[0017] 13.5 parts hardener. This can result in a coating with particularly good fire-retardant properties.

[0018] It is also advantageous if, during the application step, the fire-retardant coating is applied to the treated surface, which has a thermal conductivity of essentially 1.0 W / (m*K). Such low thermal conductivity enables good fire-retardant properties.

[0019] For example, during the application step, the fire-retardant coating can be applied to the treated surface using an airless method, compressed air, brushing, rolling, or dipping. With the airless method, the spray material can be atomized and applied to the surface under high pressure without the need for air; a nozzle bore can be > 0.127 cm. When using compressed air, a nozzle bore can be 4 mm, for example. Brushing or rolling is possible with the addition of solvents.

[0020] During the application step, the fire-retardant coating can be applied with a layer thickness of at least 300 μm. For example, during the application step, the fire-retardant coating can be applied with a layer thickness of at least 500 μm to 3000 μm or a maximum of 5000 μm. This thickness promotes the fire-retardant effect.

[0021] A fire-retardant container for a rail vehicle comprises a raw container with at least one treated surface and a fire-retardant coating. The raw container is molded from plastic, in particular from a thermoplastic. The treated surface of the raw container was created using a surface treatment of at least one surface of the raw container. The fire-retardant coating is arranged on the treated surface.

[0022] According to one embodiment, the fire-retardant container can be shaped as a washer water tank for a windscreen washer system, for example for a rail vehicle.

[0023] According to another embodiment, the fire-retardant container can be designed as a condensate tank for an air supply system. According to another embodiment, the fire-retardant container can be designed as a condensate tank for a compressed air system, for example, of a rail vehicle.

[0024] According to another embodiment, the fire-retardant container may be shaped as a waste container for a toilet system.

[0025] According to another embodiment, the fire-retardant container can be shaped as an operating fluid container or a fuel container for, for example, a rail vehicle, motor vehicle or a domestic system.

[0026] According to another embodiment, the fire-retardant container can be shaped as a drinking water container, a service water container or a grey water container.

[0027] A windshield wiper and washer system for a rail vehicle comprises the above-described fire-retardant container in one of the described variants. The windshield wiper and washer system may further comprise a filler cap for filling the fire-retardant container with fluid, a pump for pumping the fluid from the fire-retardant container to a wiper arm, the wiper arm, a wiper drive for driving the wiper arm, and / or an electronic control unit for controlling the windshield wiper and washer system.

[0028] An air supply system comprises the fire-retardant container described above in one of the described variants.

[0029] A toilet system comprises the fire-retardant container described above in one of the described variants.

[0030] Examples of the approach presented here are explained in more detail in the following description with reference to the figures. They show:

[0031] Fig. 1 shows a lateral cross-section of a fire-retardant container according to an embodiment for a rail vehicle;

[0032] Fig. 2 shows a lateral cross-section of a fire-retardant container according to an embodiment;

[0033] Fig. 3 is a schematic representation of a windscreen washer system according to an embodiment for a rail vehicle; and

[0034] Fig. 4 is a flowchart of a method according to an embodiment for producing a fire-retardant container for a rail vehicle.

[0035] In the following description of advantageous embodiments of the present approach, the same or similar reference numerals are used for the elements shown in the various figures and having a similar effect, whereby a repeated description of these elements is omitted.

[0036] Fig. 1 shows a lateral cross-section of a fire-retardant container 100 for a rail vehicle 105 according to one exemplary embodiment. For example only, the fire-retardant container 100 according to this exemplary embodiment is arranged in or on the rail vehicle 105. According to an alternative exemplary embodiment, the fire-retardant container 100 can be used in conjunction with another vehicle, for example, a commercial vehicle or another motor vehicle, or a domestic system, for example, a heating system, and / or as a condensate tank for a braking system or air supply system, or in other areas of application. According to an alternative exemplary embodiment, the fire-retardant container 100 can be used, for example, as an operating fluid tank, fuel tank, sewage tank, process water tank, or gray water tank.

[0037] The fire-retardant container 100 comprises a raw container 110 with at least one treated surface 115 and a fire-retardant coating 120. The raw container 110 is formed from plastic, in particular from a thermoplastic. The treated surface 115 of the raw container 110 was produced using a surface treatment of at least one surface of the raw container 110. The fire-retardant coating 120 is arranged on the treated surface 115.

[0038] By way of example only, the raw container 110 according to this exemplary embodiment is tank-shaped or canister-shaped, here exemplary as a rectangular-shaped container. According to this exemplary embodiment, the raw container 110 has an interior space 125 for accommodating a liquid, solid and / or gaseous medium. According to one exemplary embodiment, the interior space 125 has a capacity of several liters, for example at least 3 l. According to this exemplary embodiment, the raw container 110 has a plurality of walls 130 arranged at an angle to one another, here exemplary at right angles or parallel, of which, according to this exemplary embodiment, at least one has the treated surface 115. According to this exemplary embodiment, several of the walls 130, here for example all walls 130, have such a treated surface 115 with the fire-retardant coating 120.According to this exemplary embodiment, the treated surface 115 is arranged on an outer surface of the wall 130 facing away from the interior space 125. According to this exemplary embodiment, the fire-retardant coating 120 is applied directly, i.e., immediately, to the treated surface 115.

[0039] According to this exemplary embodiment, the treated surface 115 is formed as a roughened surface of the raw container 110 produced by means of a roughening process. Additionally or alternatively, the treated surface 115 has chemically polar structures after the surface treatment.

[0040] The fire-retardant container 100 presented here is a fire-resistant plastic container. The fire-retardant container 100 can be used as a condensate container for, for example, so-called "air supply projects," i.e., for the provision and intelligent distribution of compressed air to various consumers in the vehicle, for example, in connection with a braking system. Alternatively, the fire-retardant container 100, as shown here, can be used as a plastic tank in the rail vehicle 105.

[0041] Unlike other materials, the materials of the fire-retardant container 100 sufficiently fulfilled the required properties with regard to mechanical stresses, such as stone chip resistance, pressure stability and vibration resistance, as well as with regard to sufficient resistance to environmental influences, such as UV exposure, over the entire service life of the product.

[0042] Unlike previously offered flame-retardant plastic containers, which only meet stricter fire protection standards, the fire-retardant container presented here meets 100 extended, current fire protection requirements.

[0043] The high requirements for fire protection of plastic containers, for example in rail vehicle construction, are met by these adaptations, or rather the fire-retardant container 100.

[0044] Compared to alternative options such as a sheet metal enclosure, a container made of welded sheet material, or the bonding of fire-retardant panels, the fire-retardant container 100 presented here is particularly cost-effective. The fire-retardant container 100 also offers considerable freedom of form, and its mechanical strength, based on the substrate material, remains constant throughout the container 100, regardless of its geometry. The cost-effectiveness of its manufacturing is superior to other processes. Furthermore, the material composite of the container 100 can be repaired relatively easily.

[0045] The approach presented here consists of preparing a raw container 110 in the form of a plastic container, which was manufactured, for example, using a special injection molding process, e.g., rotomold or blowmold, from, for example, polyethylene, by means of a suitable surface pretreatment, in this case, for example, flame treatment, for the subsequent application of the fire-retardant coating 120. The subsequent application of the fire-retardant coating 120 results in an improved, fire-protection-compatible plastic container. Flame treatment of a thermoplastic increases its surface tension, which leads to better bondability or adhesion. Flame treatment is suitable for the raw container 110, which, according to various exemplary embodiments, comprises thermoplastic polymers such as, for example, polyethylene (PE) and / or polypropylene (PP) and / or polyamides (PA), and / or other plastics.According to one embodiment, the surfaces of the walls 130 were cleaned and degreased before flame treatment. According to one embodiment, a propane or acetylene flame with excess oxygen was used during the flame treatment. According to one embodiment, for example, the plastic surface was passed under the flame. Flame treatment results in visible roughening of glossy surfaces and / or chemically polar structures in the surface, which leads to an increase in surface tension. According to one embodiment, the fire-retardant coating 120 was applied to the flame-treated surface 115 immediately after flame treatment, since the pretreatment effect wears off very quickly.

[0046] According to one embodiment, the coating 120 comprises an intumescent two-component polyurethane-based compound that provides fire protection in rail vehicles. Tests have shown that surface preparation by flame treatment is required according to one embodiment; otherwise, suitable adhesion to the raw material cannot be ensured. The use of an adhesion promoter is advantageously not required. The layer thickness of the fire-retardant coating 120 according to one embodiment is at least 500 μm, up to, for example, 3000 μm, or a maximum of 5000 μm.

[0047] The fire-retardant container 100 implements a suitable and defined material composite under economically viable aspects, which meets the aforementioned requirements such as fire protection, high degree of freedom of form, mechanical strength, and the required service life. Furthermore, the material composite of the container 100 can be easily repaired.

[0048] The practical application / use of the fire-retardant container 100 is for plastic containers with high fire protection requirements,

[0049] In summary, thanks to the fire-retardant container 100, high fire protection requirements, great freedom of shape, economical manufacturability, high mechanical strength, a long service life and easy repair options can be achieved in a plastic container.

[0050] Fig. 2 shows a lateral cross-section of a fire-retardant container 100 according to one embodiment. This may be a section of a wall of the fire-retardant container 100 described in Fig. 1.

[0051] According to this exemplary embodiment, the raw container comprises a substrate 200 made of thermoplastic. According to this exemplary embodiment, the treated surface is formed as a flame-treated substrate layer 205 produced by the flame treatment described in Fig. 1, to which the fire-retardant coating 120 is applied in the form of a fire protection coating. According to this exemplary embodiment, a layer thickness of the fire-retardant coating 120 corresponds to or is similar to a layer thickness of the flame-treated substrate layer 205. According to this exemplary embodiment, the fire-retardant coating 120 comprises a two-component polyurethane-based material. It is particularly suitable for outdoor applications. This material is characterized by its high resistance to climatic and mechanical influences.

[0052] According to this embodiment, the fire-retardant coating 120 comprises a first component A, which here is, for example, a resin, and / or a second component B, which here is, for example, a hardener.

[0053] According to this embodiment, the resin density at +20°C is 1.32 to 1.36 kg / m 3 . According to this example, the hardener density at +20°C is 1.22 to 1.24 kg / m 3 . According to this embodiment, resin and / or hardener each have a thermal conductivity of substantially 1.0 W / (m*K).

[0054] According to this embodiment, the viscosity of the resin is approximately 25,000 mPa*s at +50°C. According to this embodiment, the viscosity of the hardener is approximately 100 mPa*s at +20°C.

[0055] According to this exemplary embodiment, the mixing ratio in weight % is 100 parts resin to 12.5 parts hardener. According to this exemplary embodiment, the mixing ratio in volume % is 100 parts resin to 13.5 parts hardener.

[0056] According to one embodiment, processing of the fire-retardant coating 120 at, for example, at least +5°C / < 85% relative humidity is carried out as follows:

[0057] It is ensured that a substrate, in this case the flame-exposed substrate layer 205, is free of contaminants. For easier processing, according to one embodiment, the first component A is heated to +50°C, whereby the first component A was stirred thoroughly before processing. Components A and B were mixed very thoroughly in the exact weight ratio. Application is preferably carried out using the airless method, for example with a nozzle bore of >0.127 cm. In an alternative processing method, compressed air is used for application, for example with a nozzle bore of 4 mm, or the flame-retardant coating 120 is applied by brushing or rolling, for example with the addition of solvent, or by dipping. According to one embodiment, ethyl acetate or xylene was added to the first component A. According to one embodiment, a pot life is approximately10 minutes for both components A and B at +20°C, or alternatively approximately 8 minutes if the first component A has been tempered to +50°C. A curing time at +20°C is < 24 hours until the flame-treated substrate layer 205 is load-bearing. The temperature resistance of the flame-treated substrate layer 205 during operation is -25°C to +60°C.

[0058] An example consumption is described below:

[0059] Resin: Solids (wt.): 100%, application quantity [g / m 2 ]: 1,320 g / m 2

[0060] Hardener: Layer thickness [pm] Wet: 1,000 pm, Dry: 1,000 pm

[0061] The required dry film thickness varies depending on the fire protection requirements and fire protection properties of the structures to be protected.

[0062] The product, the fire-retardant container 100, meets the extended requirements for fire protection.

[0063] Fig. 3 shows a schematic representation of a windshield wiper and washer system 300 according to an exemplary embodiment for a rail vehicle. The windshield wiper and washer system 300 comprises the fire-retardant container 100 described in one of Figures 1 or 2.

[0064] According to this exemplary embodiment, the fire-retardant container 100 is designed as a fire-protection-compatible washer water tank 305 of the windshield wiper and washer system 300. According to this exemplary embodiment, the windshield wiper and washer system 300 further comprises a filler cap 310 for filling the washer water tank 305 with washer water, a pump 315 for pumping the washer water from the washer water tank 305 to a wiper arm 320, the wiper arm 320 for cleaning a windshield 322 of the rail vehicle, a wiper drive 325 for driving the wiper arm 320, and / or an electronic control unit 330 for controlling the windshield wiper and washer system 300. According to one exemplary embodiment, the wiper drive 325 is designed as an electro-pneumatic drive. According to this exemplary embodiment, the pump 315 is arranged on and / or in the fire-retardant container / washer water tank 305.

[0065] According to this exemplary embodiment, a hose 335 fluidically connects the filler cap 335 to the washer water tank 305 and / or another hose 335 fluidically connects the washer water tank 305 to the wiper arm 320.

[0066] According to an alternative embodiment, the fire-retardant container 100 can be used in conjunction with an air supply system or toilet system for, for example, a rail vehicle, motor vehicle or a domestic system.

[0067] Fig. 4 shows a flowchart of a method 400 according to an embodiment for producing a fire-retardant container for a rail vehicle. This can be one of the fire-retardant containers described with reference to Fig. 1, 2, or 3.

[0068] The method 400 comprises an implementation step 405 and an application step 410. In implementation step 405, a surface treatment of at least one surface of a raw container made of plastic, in particular a thermoplastic, is carried out in order to produce a treated surface of the raw container. In application step 410, a fire-retardant coating is applied to the treated surface in order to produce the fire-retardant container. Optionally, the method 400 according to this exemplary embodiment further comprises a production step 415 in which the raw container is produced using a plastic material. For example, in this exemplary embodiment, the raw container is produced using an injection molding process in production step 415. According to this exemplary embodiment, production step 415 is carried out before implementation step 405.According to this exemplary embodiment, in step 405 of performing the surface treatment, a flame treatment, activation, chemical treatment, and / or mechanical treatment is carried out on at least the surface of the raw container to create the treated surface of the raw container. In step 410 of applying, according to one exemplary embodiment, the fire-retardant coating is applied with a layer thickness of at least 300 μm or at least 500 μm.

[0069] Unlike other manufacturing processes such as the processing of fire-retardant plastic sheet material, the enclosure of plastic tanks using a metal shell, the production of a container from metal, or the application of fire-retardant insulation materials to a plastic container, the process 400 presented here enables the production of more complex geometries on a diverse scale.

[0070] LIST OF REFERENCE SYMBOLS

[0071] 100 fire-retardant containers

[0072] 105 rail vehicles

[0073] 110 raw containers

[0074] 115 treated surface

[0075] 120 fire-retardant coating

[0076] 125 interior

[0077] 130 Wall

[0078] 200 substrate

[0079] 205 flame-treated substrate layer

[0080] 300 Windscreen wiper system

[0081] 305 Washer water tank

[0082] 310 filling cap

[0083] 315 Pump

[0084] 320 wiper arm

[0085] 322 disc

[0086] 325 Wiper drive

[0087] 330 electronic control unit

[0088] 335 hose

[0089] 400 Method for producing a fire-retardant container for a

[0090] Rail vehicle

[0091] 405 Step of implementation

[0092] 410 steps of application

[0093] 415 Step of creation

Claims

PATENT CLAIMS 1. Method (400) for manufacturing a fire-resistant container (100), wherein the method (400) comprises the following steps: Performing (405) a surface treatment of at least one surface of a raw container (110) made of plastic, in particular of a thermoplastic or a thermoset, to produce a treated surface (115) of the raw container (110); and Applying (410) a fire-resistant coating (120) to the treated surface (115) to produce the fire-resistant container (100).

2. Method (400) according to claim 1, comprising a production step (415) in which the raw container (110) is produced using a plastic material.

3. Method (400) according to one of the preceding claims, wherein in step (405) of carrying out the surface treatment an activation of at least one surface of the raw container (110) is carried out in order to produce the treated surface (115) of the raw container (110).

4. Method (400) according to one of the preceding claims, wherein in step (405) of carrying out the surface treatment a flame treatment is carried out at least of the surface of the raw container (110) in order to produce the treated surface (115) of the raw container (110).

5. Method (400) according to one of the preceding claims, wherein in step (405) of carrying out the surface treatment a chemical treatment, in particular with a primer, is carried out at least on the surface of the raw container (110) to produce the treated surface (115) of the raw container (110).

6. Method (400) according to one of the preceding claims, wherein in step (405) of carrying out the surface treatment a mechanical treatment, in particular by sandblasting, is carried out at least on the surface of the raw container (110) to produce the treated surface (115) of the raw container (110).

7. Method (400) according to any one of claims 2 to 6, wherein the raw container (110) is produced in step (415) of production using an injection molding process.

8. Method (400) according to one of the preceding claims, wherein in step (410) of application, a 1-component mass or a 2-component polyurethane-based mass is applied to the treated surface (115) as the flame-retardant coating (120).

9. Method (400) according to one of the preceding claims, wherein in step (410) of applying to the treated surface (115) the flame-retardant coating (120) comprising resin and / or a hardener is applied.

10. Method (400) according to one of the preceding claims, wherein in step (410) of applying to the treated surface (115) the flame-retardant coating (120) is applied which has a thermal conductivity of essentially 1.0 W / (m*K).

11. Method (400) according to one of the preceding claims, wherein in step (410) of application the fire-retardant coating (120) is applied to the treated surface (115) by airless application, by compressed air, by brushing or rolling or dipping.

12. Method (400) according to one of the preceding claims, wherein in step (410) of application the flame-retardant coating (120) is applied with a layer thickness of at least 300 pm and / or with a layer thickness of at most 5000 pm.

13. Fire-resistant container (100), wherein the fire-resistant container (100) has the following features: a raw container (110) made of plastic, in particular of a thermoplastic, with at least one treated surface (115) produced by means of a surface treatment of at least one surface of the raw container (110); and a fire-resistant coating (120) arranged on the treated surface (115).

14. Fire-resistant container (100) according to claim 13, which is configured as a wash water tank (305) for a windscreen washer system (300), as a condensate container for an air supply system, as a fecal container for a toilet system and / or for use in a rail vehicle or a truck.

15. System comprising a fire-resistant container (100) according to claim 13 or 14, wherein the system is configured as a windshield washer system (300), as an air supply system or as a toilet system.

Images