# US 2019/0168426 A1 · Fibre reinforcement of reactive foam material obtained by a double strip foam method or a block foam method

> Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt

- Number: US 2019/0168426 A1
- Document ID: US20190168426A1
- Status: Published application
- Kind: A1
- Application number: 16/303,423
- Filed: 2017-05-17
- Published: 2019-06-06
- Earliest claimed: 2016-05-25
- Assignees: BASF SE
- Applicants: BASF SE
- Inventors: Holger RUCKDAESCHEL; Alexandre TERRENOIRE; Rene ARBTER; Bangaru Dharmapuri Sriramul SAMPATH; Peter GUTMANN; Ragnar STOLL; Robert STEIN; Christophe Leon Marie HEBETTE
- Web page: https://patentgrep.com/patent/US20190168426A1

## CPC

- B29C 44/128: {Internally reinforcing constructional elements, e.g. beams}
- B29C 44/30: Expanding the moulding material between endless belts or rollers {(B29C44/203 takes precedence)}
- B29C 44/5681: {Covering the foamed object with, e.g. a lining}
- B29C 70/14: oriented
- B32B 5/022: {Non-woven fabric}
- B32B 5/18: characterised by features of a layer {of} foamed material
- B32B 5/24: one layer being a fibrous or filamentary layer
- B32B 5/245: {another layer next to it being a foam layer}
- B32B 15/046: {of foam}
- B32B 27/065: {of foam}
- B32B 27/30: comprising vinyl {(co)polymers; comprising acrylic (co)polymers}
- B32B 27/308: {comprising acrylic (co)polymers}
- B32B 27/34: comprising polyamides
- B32B 27/36: comprising polyesters
- B32B 27/38: comprising epoxy resins
- B32B 29/007: {next to a foam layer}
- C08G 18/18: containing secondary or tertiary amines or salts thereof
- C08G 18/1816: {having carbocyclic groups}
- C08G 18/4211: {derived from aromatic dicarboxylic acids and dialcohols}
- C08G 18/425: {the polyols containing one or two ether groups}
- C08G 18/4829: {Polyethers containing at least three hydroxy groups (C08G18/4833 - C08G18/5096 take precedence)}
- C08G 18/6674: {with compounds of group C08G18/3203}
- C08G 18/7664: {containing alkylene polyphenyl groups}
- C08G 18/7671: {containing only one alkylene bisphenyl group}
- C08J 9/36: After-treatment (C08J9/22 takes precedence)
- B29C 44/352: {Means for giving the foam different characteristics in different directions}
- B29C 44/5663: {by perforating the foam, e.g. to open the cells}
- B29C 44/569: {Shaping and joining components with different densities or hardness}
- B29K 2075/00: Use of {PU, i.e.} polyureas or polyurethanes {or derivatives thereof}, as moulding material
- B29K 2105/04: cellular or porous
- B29K 2105/12: of short lengths, e.g. chopped filaments, staple fibres or bristles
- B29K 2105/14: oriented
- B29K 2307/04: Carbon
- B29K 2705/00: Use of metals, their alloys or their compounds, for preformed parts, e.g. for inserts
- B29L 2031/08: Blades for rotors, stators, fans, turbines or the like, e.g. screw propellers
- B29L 2031/085: {Wind turbine blades}
- B29L 2031/30: Vehicles, e.g. ships or aircraft, or body parts thereof {(vanes or blades B29L2031/08, air bags B29L2022/027)}
- B32B 27/12: next to a fibrous or filamentary layer
- B32B 27/40: comprising polyurethanes
- B32B 2250/40: Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
- B32B 2260/023: Two or more layers
- B32B 2260/046: Synthetic resin
- B32B 2262/02: Synthetic macromolecular fibres
- B32B 2262/0238: Vinyl halide, e.g. PVC, PVDC, PVF, PVDF
- B32B 2262/0253: Polyolefin fibres
- B32B 2262/0261: Polyamide fibres
- B32B 2262/0269: Aromatic polyamide fibres
- B32B 2262/0276: Polyester fibres
- B32B 2262/0292: Polyurethane fibres
- B32B 2262/065: Lignocellulosic fibres, e.g. jute, sisal, hemp, flax, bamboo
- B32B 2262/10: Inorganic fibres
- B32B 2262/101: Glass fibres
- B32B 2262/103: Metal fibres
- B32B 2262/105: Ceramic fibres
- B32B 2262/106: Carbon fibres, e.g. graphite fibres
- B32B 2266/0214: Materials belonging to B32B27/00
- B32B 2266/0278: Polyurethane
- B32B 2266/0285: Condensation resins of aldehydes, e.g. with phenols, ureas, melamines
- B32B 2307/732: Dimensional properties
- B32B 2603/00: Vanes, blades, propellers, rotors with blades
- B32B 2605/08: Cars
- B32B 2605/10: Trains
- B32B 2605/18: Aircraft
- C08G 2101/00: Manufacture of cellular products
- C08G 2110/0025: rigid
- C08G 2110/0083: prepared using water as the sole blowing agent
- C08J 2201/022: premixing or pre-blending a part of the components of a foamable composition, e.g. premixing the polyol with the blowing agent, surfactant and catalyst and only adding the isocyanate at the time of foaming
- C08J 2205/052: Closed cells, i.e. more than 50% of the pores are closed
- C08J 2205/10: Rigid foams
- C08J 2300/24: Thermosetting resins
- C08J 2375/02: Polyureas
- C08J 2375/04: Polyurethanes
- F05B 2280/6003: Composites; e.g. fibre-reinforced
- F05B 2280/6012: Foam
- Y02E 10/72: Wind turbines with rotation axis in wind direction
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- C08G: MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08J: WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H (working, e.g. shaping, of plastics B29)
- B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- F05B: INDEXING SCHEME RELATING TO WIND, SPRING, WEIGHT, INERTIA OR LIKE MOTORS, TO MACHINES OR ENGINES FOR LIQUIDS COVERED BY SUBCLASSES F03B, F03D AND F03G
- Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION

## Abstract

The present invention relates to a molding made of reactive foam, wherein at least one fiber (F) is arranged partially inside the molding, i.e. is surrounded by the reactive foam. The two ends of the respective fiber (F) not surrounded by the reactive foam thus each project from one side of the corresponding molding. The reactive foam is produced by a double belt foaming process or a block foaming process. The present invention further provides a panel comprising at least one such molding and at least one further layer (S1). The present invention further provides processes for producing the moldings according to the invention from reactive foam/the panels according to the invention and also provides for the use thereof as a rotor blade in wind turbines for example.

## Claims

### Claim at position 1

-15. (canceled)

### Claim 16

A molding made of reactive foam, wherein at least one fiber (F) is with a fiber region (FB2) arranged inside the molding and surrounded by the reactive foam while a fiber region (FB1) of the fiber (F) projects from a first side of the molding and a fiber region (FB3) of the fiber (F) projects from a second side of the molding, wherein the reactive foam has been produced by a double belt foaming process or a block foaming process, wherein the reactive foam comprises cells, wherein at least 50% of the cells are anisotropic, wherein at least one of the mechanical properties of the reactive foam is anisotropic.

### Claim 17 (depends on 16)

The molding according to claim 16, wherein the double belt foaming process comprises the following steps I-1) to IV-1):
I-1) providing a reactive mixture which comprises at least one first component (K1) and at least one second component (K2), wherein the first component (K1) and the second component (K2) can react with one another,
II-1) introducing the reactive mixture provided in step I-1) between a lower carrier material and an upper carrier material, wherein the reactive mixture rests on the lower carrier material and wherein the upper carrier material rests on the reactive mixture,
III-1) expanding the reactive mixture between the lower carrier material and the upper carrier material to obtain an expanded foam and
IV-1) calibrating the expanded foam obtained in step III-1) between two parallel belts to obtain the reactive foam,
wherein steps III-1) and IV-1) are performed consecutively or simultaneously.

### Claim 18 (depends on 16)

The molding according to claim 16, wherein the block foaming process comprises the following steps I-2) to III-2):
I-2) providing a reactive mixture which comprises at least one first component (K1) and at least one second component (K2), wherein the first component (K1) and the second component (K2) can react with one another,
II-2) introducing the reactive mixture provided in step I-2) into a shaping mold, wherein the shaping mold has at least one open side and at least two dosed sides and
III-2) expanding the reactive mixture in the shaping mold to obtain the reactive foam,

### Claim 19 (depends on 17)

The molding according to claim 17, wherein the reactive foam is based on a polyurethane, a polyurea or a polyisocyanurate,
wherein the polyurethane, the polyurea or the polyisocyanurate is in each case produced by the double belt foaming process and where the reactive mixture provided in step I-1) comprises as the first component (K1) at least one polyisocyanate and as the second component (K2) at least one compound having isocyanate-reactive groups and as a further component at least one blowing agent.

### Claim 20 (depends on 16)

The molding according to claim 16, wherein the reactive foam comprises cells, wherein
i) at least 80% of the cells are anisotropic, and/or
ii) the ratio of the largest dimension (a-direction) to the smallest dimension (c-direction) of at least 50% of the cells is ≥1.05, and/or
iii) the mean size of the smallest dimension (c-direction) of at least 50% of the cells is in the range from 0.01 to 1 mm, and/or
iv) at least 50% of the cells are orthotropic or transversely isotropic, and/or
v) at least 50% of the cells based on their largest dimension (a-direction) are aligned at an angle γ of ≤30° or >60° relative to the thickness direction (d) of the molding, and/or
vi) the reactive foam has a closed-cell content of at least 80%, and/or
vii) the fiber (F) is arranged at an angle ε of ≤60° relative to the largest dimension (a-direction) of at least 50% of the cells of the reactive foam.

### Claim 21 (depends on 16)

The molding according to claim 16, wherein
i) the reactive foam has a thickness (z-direction) in the range of at least 10 mm, a length (x-direction) of at least 200 mm, and a width (y-direction) of at least 200 mm, and/or
ii) the surface of at least one side of the molding has at least one depression, the depression being a slot or a hole, and/or
iii) all of the mechanical properties of the reactive foam are anisotropic, and/or
iv) at least one of the elastic moduli of the reactive foam behave(s) in the manner of an anisotropic material, and/or
(v) the ratio of the compressive strength of the reactive foam in thickness (z-direction) to the compressive strength of the reactive foam in strength (x-direction) is ≥1.1, and/or
(vi) the polymer present in the reactive foam has a glass transition temperature (TG) of at least 80° C., and/or
vii) the fiber (F) is a single fiber or a fiber bundle, and/or
viii) the fiber (F) is an organic, inorganic, metallic or ceramic fiber or a combination thereof, and/or
ix) the fiber (F) is employed in the form of a fiber bundle having a number of individual fibers per bundle of at least 10 in the case of glass fibers and 1000 to 50 000 in the case of carbon fibers, and/or
x) the fiber region (FB1) and the fiber region (FB3) each independently of one another account for 1% to 45% and the fiber region (FB2) accounts for 10% to 98% of the total length of a fiber (F), and/or
xi) the fiber (F) has been introduced into the reactive foam at an angle α, of 0° to 60° or of 10° to 70° relative to the thickness direction (d) of the molding, and/or
(xii) in the molding the first side of the molding from which the fiber region (FB1) of the fiber (F) projects is opposite the second side of the molding from which the fiber region (FB3) of the fiber (F) projects, and/or
(viii) the molding comprises a multiplicity of fibers (F) and/or comprises more than 10 fibers (F) per m2,

### Claim 22 (depends on 16)

A panel comprising at least one molding according to claim 16 and at least one layer (S1).

### Claim 23 (depends on 22)

The panel according to claim 22, wherein the layer (S1) comprises at least one resin.

### Claim 24 (depends on 23)

The panel according to claim 23, wherein the layer (S1) additionally comprises at least one fibrous material, wherein
i) the fibrous material comprises fibers in the form of one or more laminas of chopped fibers, webs, scrims, knits and/or weaves, and/or
ii) the fibrous Material comprises organic, inorganic, metallic or ceramic fibers.

### Claim 25 (depends on 22)

The panel according to claim 22, wherein the panel has two layers (S1) and the two layers (S1) are each mounted on a side of the molding opposite the respective other side in the molding.

### Claim 26 (depends on 17)

A panel comprising at least one molding according to claim 17 and at least one layer (S1) wherein
i) the fiber region (FB1) of the fiber (F) is in partial or complete contact with the first layer (S1), and/or
ii) the fiber region (FB3) of the fiber (F) is in partial or complete contact with the second layer (S1), and/or
iii) the panel comprises between at least one side of the molding and at least one layer (S1) at least one layer (S2), the layer (S2) being composed of sheetlike fiber materials or polymeric films, and/or
iv) the panel comprises between at least one side and at least one layer (S1) at least one layer (S2), wherein the at least one layer (S2) was applied to the reactive foam of the molding of the panel as the upper carrier material and/or as the lower carrier material in step II-1) of the double belt foaming process, and/or
v) the molding present in the panel comprises at least one side that has not been subjected to mechanical and/or thermal processing.

### Claim 27 (depends on 16)

A process for producing a molding according to claim 16, wherein at least one fiber (F) is partially introduced into the reactive foam with the result that the fiber (F) is with the fiber region (FB2) arranged inside the molding and surrounded by the reactive foam while the fiber region (FB1) of the fiber (F) projects from a first side of the molding and the fiber region (FB3) of the fiber (F) projects from a second side of the molding.

### Claim 28 (depends on 27)

The process according to claim 27, wherein the partial introduction of at least one fiber (F) into the reactive foam is effected by sewing-in using a needle, partial introduction being effected by steps a) to f):
a) optionally applying at least one layer (S2) to at least one side of the reactive foam,
b) producing one hole per fiber (F) in the reactive foam, wherein the hole extends from a first side to a second side of the reactive foam and optionally through the layer (S2),
c) providing at least one fiber (F) on the second side of the reactive foam,
d) passing a needle from the first side of the molding through the hole to the second side of the reactive foam and optionally passing the needle through the layer (S2),
e) securing at least one fiber (F) to the needle on the second side of the reactive foam and returning the needle including the fiber (F) through the hole, so that the fiber (F) is with the fiber region (FB2) arranged inside the molding and surrounded by the reactive foam while the fiber region (FB1) of the fiber (F) projects from a first side of the molding and the fiber region (FB3) of the fiber (F) projects from a second side of the molding,
wherein steps b) and d) are optionally performed simultaneously.

### Claim 29 (depends on 22)

A process for producing a panel according to claim 22, wherein the at least one layer (S1) is produced, applied and cured on the at least one molding in the form of a reactive viscous resin, by liquid impregnation methods.

### Claim 30 (depends on 16)

A rotor blade in a wind turbine comprising the molding according to claim 16.

### Claim 31 (depends on 18)

The molding according to claim 18, wherein the reactive foam is based on a polyurethane, a polyurea or a polyisocyanurate,
wherein the polyurethane, the polyurea or the polyisocyanurate is in each case produced by the block foaming process and where the reactive mixture provided in step I-2) comprises as the first component (K1) at least one polyisocyanate and as the second component (K2) at least one compound having isocyanate-reactive groups and as a further component at least one blowing agent.