# US 7,459,115 B2 · Method for producing composite elements

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- Number: US 7,459,115 B2
- Document ID: US7459115B2
- Status: Granted
- Kind: B2
- Application number: 10/514,565
- Filed: 2003-06-04
- Published: 2005-11-03
- Granted: 2008-12-02
- Earliest claimed: 2002-06-06
- Assignees: BASF SE
- Inventors: Edmund Stadler; Peter Reinerth; Armin Deininger; Armin Reindl
- Web page: https://patentgrep.com/patent/US7459115B2

## CPC

- B29C 39/025: {for making multilayered articles}
- B29C 39/126: {by casting between two preformed layers, e.g. deformable layers (between two glass layers B32B17/10917)}
- B32B 15/08: of synthetic resin
- B32B 15/10: of wood
- B32B 2605/12: Ships
- Y10T 428/12: All metal or with adjacent metals
- Y10T 428/31551: Of polyamidoester [polyurethane, polyisocyanate, polycarbamate, etc.]
- 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
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

In a process for the production of composite elements which have the following layer structure: (i) from 2 to 20 mm of metal, plastic or wood, (ii) from 10 to 300 mm of plastic and (iii) from 2 to 20 mm of metal, plastic or wood, the starting materials for the production of (ii) are introduced in the liquid state in at least two steps into the space between (i) and (iii), the space to be filled in the last filling process having a volume of from 0.1 to 1.5 m3 and the height of the space to be filled being less than 25 mm.

## Claims

### Claim 1

A process for the production of a composite element having a layer structure comprising:
layer (i) which comprises from 2 to 20 mm of metal, plastic or wood,
layer (ii) which comprises from 10 to 300 mm of plastic and
layer (iii) which comprises from 2 to 20 mm of metal, plastic or wood;
said process comprising:
introducing one or more starting materials in a liquid state for the production of said layer (ii), in at least two filling steps, into a space between said layer (i) and said layer (iii),
a space to be filled in the last filling step having a volume of from 0.1 to 1.5 m3,
the height of said space to be filled in said last filling step being in a range of from 10 mm to less than 25 mm and
said layer (i) and said layer (iii) being aligned horizontally and having a deviation of in each case less than 0.5° from a horizontal plane.

### Claim 2 (depends on 1)

The process as claimed in claim 1, wherein, in each of said at least two filling steps, from 0.1 to 1.5 m3 of said one or more starting materials in a liquid state for the production of said layer (ii) are introduced and the height of said space to be filled in said last filling step is in a range of from 10 mm to less than 25 mm.

### Claim 3 (depends on 1)

The process as claimed in claim 1, wherein said at least two filling steps comprise a filling step (x) and a subsequent filling step (x+1), wherein after said filling step (x), said subsequent filling step (x+1) is not carried out until said one or more starting materials in a liquid state in said filling step (x) have reacted to give said plastic comprised in said layer (ii) to such an extent that said one or more starting materials in the liquid state in said filling steps (x) and (x+1) cannot mix with one another.

### Claim 4 (depends on 1)

The process as claimed in claim 1, wherein said space between said layer (i) and said layer (iii) has a width of from 0.5 to 4 m, a length of from 1 to 12 m and a height of from 20 to 150 mm.

### Claim 5 (depends on 1)

The process as claimed in claim 1, wherein said layer (ii) comprises one or more polyisocyanate polyadducts obtained by reacting said one or more starting materials comprising (a) one or more isocyanates and (b) one or more compounds reactive toward said one or more isocyanates.