Composite panel

Abstract

The invention relates to a composite panel comprising an anti-wear panel (1) made of thermoplastic polyurethane and a second panel (2) made of sound-absorbing material bonded to the anti-wear panel (1). The invention also relates to a production method and to uses of the composite panel.

Description

[0001] Composite panel

[0002] The invention relates to a composite panel consisting of a wear-resistant upper layer and a sound-insulating lower layer.

[0003] The object underlying the invention is to improve wear protection plates and to expand their areas of application.

[0004] To solve this problem, it is proposed to bond a wear-protection plate made of thermoplastic polyurethane to a second plate made of a sound-insulating material. In particular, the sound-insulating material serves to reduce structure-borne noise.

[0005] The panel made of a sound-insulating material is preferably an anti-noise panel based on bitumen / plastic.

[0006] Bitumen-impregnated wool felt boards or polymer-modified bitumen foils are particularly suitable as anti-noise panels.

[0007] While anti-noise plates according to the prior art are attached to the unclaimed back side of thin-walled sheets, the anti-noise plate in the present invention is located on the claimed side, protected behind the wear protection plate.

[0008] Thermoplastic polyurethane films (TPU films), which are commercially available under the name LYNX Lining, are particularly suitable as wear protection plates.

[0009] The thickness of the anti-noise plate is preferably in the range of 1.4 mm to 6 mm.

[0010] The second plate preferably has a higher specific gravity than the wear protection plate. The density of the second plate can be in the range of 1.5 kg / dm 3 up to 2 kg / dm 3 lay .

[0011] Bonding is preferably carried out using a double-sided adhesive film, such as double-sided adhesive tape. Alternatively, bonding can also be carried out using adhesives.

[0012] In another variant, combined bonding can be achieved using a double-sided adhesive film and an adhesive film. The double-sided adhesive film is preferably applied to the second plate, and the wear-protection plate is provided with an adhesive film. The adhesive film can be formed by a spray adhesive or a contact adhesive.

[0013] Less preferably, the second plate can be a foam layer. In one embodiment, in addition to the second plate in the form of the anti-noise plate, a foam layer can be present, in particular between the wear protection plate and the anti-noise plate. The wear protection plate and the foam plate or foam film can be bonded using a two-component adhesive. The foam is, in particular, a PUR foam as a damping layer. This foam layer helps, in particular, to reduce impact energy in order to further reduce wear on the TPU surface.

[0014] Depending on the thickness and material of the second plate, it can be flexible or rigid.

[0015] In a preferred embodiment, the side of the second plate facing away from the wear protection plate is adhesive, with a removable release film being present here. The adhesive free side of the second plate can preferably be formed by a double-sided adhesive film. Even at this point, the bonding can be carried out less preferably with adhesives. In another variant, a combined bonding can be carried out with a double-sided adhesive film and an adhesive film. In this case, the double-sided adhesive film is present on the second plate and the surface to which the composite plate in question is attached can be provided with an adhesive film. The adhesive film can be a spray adhesive or a

[0016] Contact adhesive can be used. The invention comprises a method for producing the wear protection plate with a second plate made of a sound-insulating material, which is characterized in that the wear protection plates are extruded in at least three different thicknesses, wherein one of the at least three different thicknesses is selected depending on the requirements of the wear layer and is glued flat to the second plate made of a sound-insulating material. The wear protection plates are preferably available in thicknesses of 1 mm, 2 mm, 3 mm, 5 mm, 8 mm and / or 10 mm.

[0017] The composite panel in question can be glued to different materials, in particular to metal surfaces, aluminum, copper, hard plastics, wood surfaces, plasterboard or to the surface of a component made of fiber composite material.

[0018] Preferred applications of the wear protection plate with the bonded second plate made of a sound-absorbing material include lining machine components such as hoppers and containers, which are subject to wear from impacting objects. The structure-borne noise of the machine component and / or the sound of the impacting objects is dampened by the sound-absorbing material. The lining of dump trucks and transport trailers is particularly advantageous. Other areas of application include truck linings or linings of chutes, wagons, silos, channels, pipes, magnetic separators, drums, crushers, sorters, or sludge chutes.

[0019] Another preferred application is impact and noise protection in sports facilities, gymnasiums, or playgrounds. The wear and weather resistance of the wear protection plate is advantageous here, protecting the underlying dampening material from environmental influences and violent impact.

[0020] Another preferred application is protective covers or mats, especially for hail protection. In this case, a thin wear-resistant plate, particularly with a thickness of 0.8-3 mm, can be attached to a second damping plate.

[0021] In one embodiment, the layered structure additionally comprises at least one layer of a fiber composite material or woven fabric. The layer of the fiber composite material or woven fabric can be located between the wear protection plate and the second plate or on the side of the second plate facing away from the wear protection plate.

[0022] The fiber composite material can, in particular, be carbon fiber reinforced plastic (CFRP). However, plastics reinforced with other fibers are also conceivable.

[0023] In one embodiment, the invention relates to a transportable mat, in particular as a gymnastics mat, insulation mat or yoga mat, which consists of a thin layer of a TPU wear protection plate with a thickness of 0.8 to 2 mm, which is provided on one side with a flexible plate made of polyurethane foam (PUR foam). The bonding can preferably be carried out using an adhesive, in particular a two-component adhesive. In another embodiment, the bonding is carried out using double-sided adhesive tape. It is advantageous that a TPU wear protection plate with a thickness of 0.8 to 2 mm can be rolled up. On the side of the flexible plate made of polyurethane foam facing away from the wear protection plate, there can be a cover layer made of a third material, for example in the form of a textile, a film or a coating.

[0024] The invention is illustrated by drawings:

[0025] Fig. 1: Illustrates the preferred construction of a wear protection plate with a second plate made of a sound-insulating material.

[0026] Fig. 2: Illustrates a composite panel comprising an additional carrier layer. Fig. 3: Illustrates a composite panel comprising an additional carrier layer and an additional damping layer.

[0027] Fig . 4 : Illustrates an application of a physical

[0028] Composite panel as base foot.

[0029] Fig . 5 : Illustrates an application of a physical

[0030] Composite panel as body protection.

[0031] Fig. 6: Illustrates a further embodiment of a composite panel on a component.

[0032] Fig . 7 : Illustrates another variant of the

[0033] Bonding a TPU wear protection plate.

[0034] As illustrated in Fig. 1, the composite panel in question comprises a wear protection plate 1 and a second plate 2 made of a sound-insulating material, in particular in the form of an anti-noise plate.

[0035] A double-sided adhesive film 3 is preferably present between the wear protection plate 1 and the second plate 2.

[0036] On the side of the second plate 2 facing away from the wear protection plate 1, there is preferably another double-sided adhesive film 4 or an adhesive substance.

[0037] The adhesive film 4 or adhesive substance may be covered with a removable release film 5 before the plate is applied at the place of use.

[0038] The second plate 2 can be in the form of an anti-noise plate with a textured surface, for example, with a diamond pattern. In this case, too, applying an adhesive film to the surface to be bonded may be useful.

[0039] Mechanical fastening of the composite panel in question to a surface is also possible, for example by means of fastening elements such as screws, rivets, nails or dowels or by positively inserting the composite panel into a recess or guide of a component.

[0040] Fig. 2 shows a variant embodiment in which the composite panel comprises, in addition to the wear protection panel 1 and a second panel 2 made of a sound-insulating material, a carrier layer 6, which carrier layer 6 is present on the side of the second panel 2 facing away from the wear protection panel 1. The second panel 2 is preferably an anti-noise mat.

[0041] The adhesive layers between the layers are not shown. These can be bonded, as already described, by adhesive application (e.g., two-component adhesive, spray adhesive, or solvent-based adhesive) and / or by double-sided adhesive films.

[0042] In one embodiment, the carrier layer 6 is a carrier sheet, which preferably has a thickness of 1 mm to 3 mm.

[0043] In one embodiment, the carrier layer 6 is a fiber-reinforced plastic (e.g., GRP or CFRP).

[0044] In one embodiment, the carrier layer 6 is a fleece.

[0045] The composite panel of Fig. 3 has, in addition to the composite panel of Fig. 2, an additional damping layer 7, in particular in the form of a PUR foam layer.

[0046] The damping layer 7 is preferably located between the wear protection plate 1 and a second plate 2 designed as an anti-noise mat. Less preferably, the damping layer 7 can be located between the second plate 2 and the carrier layer 6.

[0047] Fig. 4 shows an advantageous application of a composite panel as a support foot. The composite panel is preferably designed according to the variant described in Fig. 3. Less preferably, the composite panel can also be designed according to one of the other variants described herein.

[0048] The composite panel is attached to a component 8 of a device. Attachment can be achieved by gluing or, as shown, by fastening elements such as screws or threaded bolts.

[0049] The advantage is the isolation of noise and vibrations and the prevention or reduction of wear on the support feet. These support feet are particularly advantageous for heat pumps and air conditioning units, since replacing the support feet may require replacing the refrigerant.

[0050] Fig. 5 shows an advantageous application of a composite panel as body protection. The composite panel is preferably designed according to the variant described in Fig. 2. Less preferably, the composite panel can also be designed according to one of the other variants described herein. Attachment can again be achieved by gluing or by fastening elements such as screws, threaded bolts, rivets, etc.

[0051] The composite panel is preferably attached to a component 8 of a vehicle.

[0052] The composite panel provides protection against stone chips and reduces noise.

[0053] A preferred use is as stone chip protection on

[0054] Lightweight vehicles.

[0055] A preferred use is as underbody protection on

[0056] Lightweight vehicles or electric vehicles.

[0057] A preferred use is as a spoiler above the cab of a truck.

[0058] Generally, the composite panel can be used on the body of cars, electric cars, railways and buses.

[0059] In these applications, the composite panel preferably comprises a wear-protection panel 1, a second panel 2 made of PUR foam, and a carrier layer 6. Additionally, a further second panel 2 in the form of an anti-noise mat may be present. In this case, the second panel 2 made of PUR foam can be considered an additional damping layer 7 to the second panel 2 in the form of an anti-noise mat.

[0060] This is because the damping effect (against shocks and vibrations) of the PUR foam layer is more pronounced than that of the anti-noise mat. Conversely, the sound-insulating or noise-reducing effect of the anti-noise mat is more pronounced than that of the PUR foam layer. Therefore, when both layers are present, the anti-noise mat is considered a second panel 2 and the PUR foam layer an additional damping layer 7.

[0061] A further manufacturing variant can consist of two or more layers being produced by co-extrusion, instead of producing all the layers of the composite panel individually and gluing them together. This can be done by co-extruding the wear protection panel 1 with the second panel 2. This can be done by co-extruding the second panel 2 with a carrier layer 6. This can be done by co-extruding the wear protection panel 1, the second panel 2 and a carrier layer 6. In these cases, the carrier layer 6 can in particular be a carrier fleece.

[0062] Fig. 6 illustrates a less preferred embodiment variant in which the wear protection plate 1 is followed by the second plate 2 made of sound-insulating material, in particular as an anti-noise plate, wherein the second plate 2 is followed by the carrier layer 6 and after the carrier layer 6 by a damping layer 7, in particular made of PUR foam. The composite plate can be fastened to a component 8, wherein the damping layer 7 faces the component 8. The composite plate of Fig. 6 is particularly suitable for the uses described for the variants of Figs. 4 and 5. As a modification of the composite plate of Fig. 6, the damping layer 7 can be arranged between the wear protection plate

[0063] 1 and the carrier layer 6 and the second plate 2 on the side of the carrier layer 6 facing away from the damping layer 7.

[0064] Fig. 7 illustrates a TPU wear protection plate 1 provided with an adhesive layer 9. The adhesive layer 9 serves to bond the TPU wear protection plate 1 with solvent adhesives instead of having to use a two-component adhesive. The layer thickness of the adhesive layer 9 can

[0065] 2 mm. The adhesive layer 9 can consist of cellulose nitrate (CN). With this adhesive layer 9, the TPU wear protection plate 1 can be bonded to materials such as rubber or metal without complex surface preparation by roughening.

[0066] TPU wear protection plates 1 with an adhesive layer 9 offer an alternative for bonding materials that are not suitable for bonding with 2K adhesives, for example.

[0067] Preferably, there is a release film on the adhesive layer 9, which is removed before the solvent adhesive is applied.

[0068] TPU wear protection plates 1 with or without an adhesive layer 9 can be bonded with rubber of various Shore hardnesses. Thus, TPU wear protection plates can be manufactured with an elastic rubber damping layer (sandwich plates).

[0069] When bonding TPU wear protection plates 1 with and without adhesive layer 9 with solvent adhesive, there is the disadvantage that very precise work must be carried out, since the bonded TPU wear protection plates 9 do not allow any further lifting or displacement from the adhesive surfaces.

[0070] This represents a disadvantage when complex geometries that do not allow for joints or gaps are to be bonded. For large-area cladding with TPU wear protection plates 1 with and without an adhesive layer 9, a 2-component adhesive is more suitable for bonding the TPU wear protection plates 1.

[0071] In the variants of Fig. 1-6, an additional adhesive layer 9 may be present, which in the layer structure immediately follows the wear protection plates 1.

Claims

Patent claims 1. Composite panel, characterized in that it comprises a wear protection plate (1) made of thermoplastic polyurethane and a second plate (2) made of sound-insulating material.

2. Composite panel according to claim 1, characterized in that the second panel (2) is an anti-drum panel.

3. Composite panel according to claim 2, characterized in that the anti-drumming panel comprises a bitumen-impregnated wool felt board or a polymer-modified bitumen foil.

4. Composite panel according to one of claims 1 to 3, characterized in that the wear protection plate (1) and the second plate (2) are glued to one another, in particular with a double-sided adhesive film (3).

5. Composite panel according to one of claims 1 to 4, characterized in that it additionally comprises at least one layer of a fiber composite material.

6. Composite panel according to one of claims 1 to 5, characterized in that the side of the second panel (2) facing away from the wear protection panel (1) is adhesive, in particular by a double-sided adhesive film (4).

7. Composite panel according to one of claims 1 to 6, characterized in that the composite panel comprises, in addition to the second panel (2), a damping layer (7) made of PUR foam.

8. Composite plate according to one of claims 1 to 6, characterized in that the composite plate additionally comprises a carrier layer (6), wherein between the wear protection plate (1) and the carrier layer (6) the second plate (2) and / or a damping layer (7) made of PUR foam.

9. Composite panel according to claim 8, characterized in that the carrier layer (6) is a carrier sheet.

10. Composite panel according to claim 8, characterized in that the carrier layer (6) is a carrier fleece.

11. Composite panel according to claim 8, characterized in that the carrier layer (6) is a fiber-reinforced plastic.

12. Composite panel according to one of claims 1 to 11, characterized in that the wear protection plate (1) has an adhesive layer (9) made of a material which is different from the material of the wear protection plate (1) and is better suited for bonding with a solvent adhesive, in particular made of cellulose nitrate.

13. A method for producing a composite panel according to one of claims 1 to 12, characterized in that wear protection panels (1) are extruded in at least three different thicknesses, wherein, depending on the requirements of the wear layer, one of the at least three different thicknesses is selected and combined with the second panel (2) made of a sound-insulating material, wherein optionally an additional combination with a damping layer (7) and / or a carrier layer (6) takes place in a selectable order.

14. Use of a composite panel according to one of claims 1 to 12, characterized in that it is fastened to the stressed side of a surface of an object, the wear protection plate (1) being located on the side of the composite panel facing away from the surface of the object.

15. Use of a composite panel according to claim 14, characterized in that the object is a machine component which is subjected to wear by impacting objects.

16. Use of a composite panel according to claim 14, characterized in that the composite panel is a support foot which is present between a device and a base.

17. Use of a composite panel according to claim 16, characterized in that the device is a heat pump or an air conditioning device.

18. Use of a composite panel according to claim 14, characterized in that the composite panel is attached to a body of a vehicle.

19. Use of a composite panel according to claim 14, characterized in that the composite panel is present on the underbody of a vehicle.

20. A transportable composite mat, in particular as a gym mat, insulation mat or yoga mat, characterized in that it comprises a wear protection plate (1) made of thermoplastic polyurethane and a second plate (2) in the form of a layer of PUR foam glued to this wear protection plate (1), wherein the wear protection plate (1) has a thickness in the range of 0.8 mm to 2 mm, so that the Composite mat can be rolled up.

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