Method of manufacturing a composite foam from foam flakes, composite foam, and use of this composite foam
AssigneeStankiewicz GmbH
InventorsCarsten Kliwer, Christoph Kittel
Life of this patent
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Abstract
For manufacturing a composite foam, having acoustic properties, foam flakes (8) of differing sizes, differing origins, and/or differing material compositions are wetted with a small quantity of a polyurethane dispersion binding agent. The mixture is subsequently combined to a molded part (1) or to continuous web and under the effect of hot (water) steam or microwave energy is cured and subsequently dried. The composite foam can be used for sound insulation purposes in vehicles and in general machinery construction, and also in building construction.
Claims11
A method of manufacturing a composite foam having a density, elastic modulus and loss factor so as to provide a finished composite foam product having sound dampening acoustical properties, said method comprising the steps of:
- (a) wetting reclaimed foam flakes of differing reclamation origins with 5 wt. % to 20 wt %, based on the weight of the foam flakes, of an aqueous polyurethane dispersion binding agent, said binding agent comprising a 1:1 mixture with water of an NCO-prepolymer with blocked isocyanate groups and containing a polyamine component having primary and/or secondary (cyclo) aliphatically bonded amino groups;
- (b) forming the wetted foam flakes into a molded part or continuous web;
- (c) hardening the molded part or continuous web by applying hot (water) steam or microwave energy;
- and
- (d) drying the hardened molded part or continuous web with hot air and/or vacuum,
- wherein the density is greater than 150 kg/m3, the elastic modulus is in the range between 50,000 and 140,000 N/m2 and the loss factor is greater than 0.2.
A method of manufacturing a composite foam having a density, elastic modulus and loss factor so as to provide a finished composite foam product having sound dampening acoustical properties, said method comprising the steps of:
- (a) wetting reclaimed foam flakes of differing sizes, differing origins, and differing material compositions with 5 wt. % to 20 wt %, based on the weight of the foam flakes, of an aqueous polyurethane dispersion binding agent, said binding agent comprising a 1:1 mixture with water of an NCO-prepolymer with blocked isocyanate groups and containing a polyamine component having primary and/or secondary (cyclo) aliphatically bonded amino groups;
- (b) forming the wetted foam flakes into a molded part or continuous web;
- (c) hardening the molded part or continuous web by applying hot (water) steam or microwave energy;
- and
- (d) drying the hardened molded part or continuous web with hot air and/or vacuum,
- wherein the density is greater than 150 kg/m3, the elastic modulus is in the range between 50,000 and 140,000 N/m2 and the loss factor is greater than 0.2.
Dependencies are inferred from the claim text.