Method of making a building panel and the panel
11731322 ยท 2023-08-22
Assignee
Inventors
Cpc classification
B29C44/46
PERFORMING OPERATIONS; TRANSPORTING
B60K16/00
PERFORMING OPERATIONS; TRANSPORTING
B32B2255/10
PERFORMING OPERATIONS; TRANSPORTING
B29C44/445
PERFORMING OPERATIONS; TRANSPORTING
B29C70/78
PERFORMING OPERATIONS; TRANSPORTING
B29C51/082
PERFORMING OPERATIONS; TRANSPORTING
B29L2031/10
PERFORMING OPERATIONS; TRANSPORTING
B29C44/1271
PERFORMING OPERATIONS; TRANSPORTING
H02S20/30
ELECTRICITY
B29C70/682
PERFORMING OPERATIONS; TRANSPORTING
B29C70/021
PERFORMING OPERATIONS; TRANSPORTING
H01L31/0481
ELECTRICITY
Y02T10/90
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
B29K2075/00
PERFORMING OPERATIONS; TRANSPORTING
Y02E10/50
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
B29C2033/385
PERFORMING OPERATIONS; TRANSPORTING
B29C44/3426
PERFORMING OPERATIONS; TRANSPORTING
B29C43/183
PERFORMING OPERATIONS; TRANSPORTING
B29C44/5681
PERFORMING OPERATIONS; TRANSPORTING
B29C44/14
PERFORMING OPERATIONS; TRANSPORTING
B29C51/266
PERFORMING OPERATIONS; TRANSPORTING
Y02B10/10
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
B60L8/003
PERFORMING OPERATIONS; TRANSPORTING
B60R16/03
PERFORMING OPERATIONS; TRANSPORTING
Y02T10/7072
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
International classification
B29C44/12
PERFORMING OPERATIONS; TRANSPORTING
B29C44/46
PERFORMING OPERATIONS; TRANSPORTING
B29C44/56
PERFORMING OPERATIONS; TRANSPORTING
B29C51/08
PERFORMING OPERATIONS; TRANSPORTING
B29C51/26
PERFORMING OPERATIONS; TRANSPORTING
B29C70/02
PERFORMING OPERATIONS; TRANSPORTING
B29C70/68
PERFORMING OPERATIONS; TRANSPORTING
B29C70/78
PERFORMING OPERATIONS; TRANSPORTING
B60K16/00
PERFORMING OPERATIONS; TRANSPORTING
Abstract
The invention relates, among other things, to a method of making a thin panel (10) for outdoor applications, comprising, among other things, the following steps: a) providing a deep-drawable film (10) of a transparent plastic, b) deep-drawing the film (11) in a mold (34), c) mounting a structure (19) having solar cells (32) on an inner face (16) of the deep-drawn film (12), d) placing the deep-drawn film (12) with mounted structure (19) in a cavity (33) of a mold (34) having in particular at least two mold halves (13, 14), e) introducing a liquid polyurethane casting compound (24) into the cavity (33) of the mold (34) and spreading the polyurethane casting compound (24) over an inner face (18) of the structure (19) and/or over the inner face (16) of the film (12), f) curing the polyurethane casting compound, in particular with the mold closed, to form a reinforcement layer (30), or comprising the following steps j) and k) instead of the steps e) and f): j) introducing a granular particle foam mass into the cavity (33) of the mold (34) and spreading over an inner face (18) of the structure (19) and/or over the inner face (16) of the film (12), k) baking and curing the particle foam mass, in particular with the mold closed, to form a reinforcement layer (30).
Claims
1. A method comprising the following steps: a) providing a deep-drawable film of a transparent plastic, b) deep-drawing the film, c) mounting a structure having solar cells on an inner face of the deep-drawn film with an inner face of the structure turned away from the film and an outer face of the structure on or closely juxtaposed with the inner face of the film, d) placing the deep-drawn film with the mounted structure in a cavity of a mold having at least two mold halves, e) introducing foamable granular particles into the cavity of the mold and spreading the granular particles over the inner face of the structure in direct contact with the inner face of the structure without the interposition of an adhesive, f) heating the mold and thereby conductively heating and foaming the granular particles in the cavity into a foam mass, g) curing the foam mass with the mold closed to form a reinforced panel, and h) removing the reinforced panel from the mold.
2. The method according to claim 1, wherein the film consists of polycarbonate or PMMA.
3. The method according to claim 1, further comprising the step of: gluing the outer face of the structure on the inner face of the deep-drawn film.
4. The method according to claim 1, wherein before step e) the following step is performed: i) introducing a liquid barrier layer casting compound of polyurethane into the cavity of the mold and spreading the barrier layer casting compound over the inner face of the structure or over the inner face of the film, the granular particles being subsequently spread in step e) over the liquid barrier layer.
5. The method according to claim 1, wherein before step e) the following step is performed: i) introducing a liquid in-mold-paint casting compound into the cavity of the mold and spreading the in-mold-paint casting compound over the inner face of the structure or over the inner face of the film, the foamable granular particles being subsequently spread in step e) over the casting compound.
6. The method according to claim 5, wherein the step i) is performed after the step of: j) introducing a liquid barrier layer casting compound of polyurethane into the cavity of the mold and spreading the barrier layer casting compound over an inner face of the structure or over an inner face of the film.
7. The method according to claim 1, wherein the steps b) and d) and e) are performed in the same mold.
8. The method according to claim 1, wherein the step b) is carried out in a first mold and steps d) and e) are performed in a second mold and the deep-drawn film is passed from the first mold to the second mold after the step b) to perform the steps d) and e).
9. The method according to claim 1, further comprising the step of: providing electrical lines connected to the structure.
10. The method according to claim 9, wherein at least a section of the lines passes through the foam mass.
11. The method according to claim 10, wherein the foam mass has a passage for the electrical lines.
12. The method according to claim 1, further comprising the step of: using the reinforced panel as an exterior panel for cars, commercial vehicles, trailers, or agricultural machines, or as a roof element, a side wall element, an engine hood, a trunk lid, a fender or a trim part for a vehicle.
13. The method according to claim 1, further comprising the step of: using the panel after removal from the mold as a vehicle exterior body part.
Description
(1) Further advantages of the invention become apparent from the non-cited subclaims and with reference to the following description of the embodiments illustrated in the drawings. Shown are:
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22) Embodiments of the invention are described by way of example in the following description of the figures, also with reference to the drawings. For reasons of clarity, identical or comparable parts or elements or regions are also designated with the same reference numerals, sometimes with the addition of small letters, even if different embodiments are involved.
(23) Features which are described only in relation to one embodiment can also be provided in the context of the invention in any other embodiment of the invention. Such modified embodiments are comprised by the invention, even when they are not shown in the drawings.
(24) All disclosed features are essential to the invention. In the disclosure of the application, the disclosure content of the associated priority documents (copy of the prior application) and the cited references and the described devices of the prior art are hereby incorporated in full, also for the purpose, to include individual or multiple features of these documents in one or more claims of the present application.
(25) First, the family of embodiments according to
(26) The panel according to the invention is designated by the reference numeral 10 in the drawings as a whole.
(27) Such a panel is shown in the finished made state in
(28) The width B and the length L can be, for example, 5 to 1000 times the total wall thickness GW.
(29) To manufacture the panel 10 according to
(30) Starting from
(31) The deep-drawable film 11 is inserted into a mold having a lower mold 13 and an upper mold 14 according to
(32) The invention also comprises deep-drawing steps, in which, the shaping of the deep-drawable film 11 is achieved as a result of a blow molding operation, starting from a planar state that lies flat, into the desired three-dimensional shape. The mold 13 can be tempered for this purpose, and for example, suction devices can be present to pull up the outer side 15 of the deep-drawable film 11 to the inner face 36 of the lower mold 13. In such deep-drawing operations that take place in the manner of blowing operations, an upper mold 14 is not or not necessarily mandatory.
(33)
(34) The deep-drawn film 12 is shown, for illustrative purposes only, slightly spaced from the lower mold 13.
(35) Subsequently, according to a variant of the invention, the deep-drawn film 12 can be removed from the mold. In another variant of the invention, the deep-drawn film 12 can remain in the lower mold 13.
(36) In a further step, a structure 19 having solar cells 32 is now mounted to the inner face 16 of the deep-drawn film 12.
(37) The structure 19 can consist exclusively of solar cells 32, or can comprise solar cells 32. The structure 19 can be provided as a handling unit. In particular, it can be configured as a planar element that can possibly also be conformable to the contour of the inner face 16 of the deep-drawn film 12. The structure 19 can be provided as an adhesive film. In a variant of the invention, the structure 19 can be a composite panel which, in addition to the actual solar cells 32 serving to generate electricity, also comprises plastic panels, carrier materials, substrates or the like on which the solar cells 32 are mounted.
(38) In the simplest case, the structure 19 is mounted to the inner face 16 of the deep-drawn film 12 by means of a gluing operation. For this purpose, the outer side 17 of the structure 19 can be provided with an adhesive layer and/or the inner face 16 of the deep-drawn film 12 can be provided with a corresponding adhesive layer. Alternatively, it is also possible for the structure 19 to be overlaid or covered on its outer side 18 by a carrier material which overlaps the structure 19 on the outer side and is glued to the inner face 16 of the film 12.
(39) The invention also comprises when the mounting of the structure 19 to the deep-drawn film 12 is carried out only for the purpose of achieving a kind of pre-assembly state, so that position retention is achieved only for a short period of time. In one variant of the invention, it is therefore sufficient if the structure 19 is only placed on the inner face 16 of the deep-drawn film for a short time.
(40) According to a further method step, which is explained with reference to
(41) In one variant of the invention, the mold 34 can be the same mold shown in
(42) In a variant of the invention, the deep-drawn film 12 is removed from the mold shown in
(43)
(44) According to the invention, a mixing head 20 is provided, to which liquid polyurethane casting compound is supplied via a supply line 21, optionally also supplying reinforcing fibers.
(45) A mixture of the polyol panel and the isocyanate panel preferably is carried out only in the mixing head.
(46) To avoid repetition, reference is made to the Applicant's numerous patent applications mentioned above, which explain this mixing operation and the chemical processes in detail.
(47) The mixing head 20 is, as indicated schematically by the movement direction arrow 23, movable over the inner face 16 of the deep-drawn film 12 or over the inner face 18 of the structure 19. A discharge device 22 is assigned to the mixing head 20, with which discharge device the liquid polyurethane casting compound 24 can be dispensed.
(48) The introduction operation of the liquid polyurethane casting compound 24 is completed when a substantially full-surface application is achieved. The invention also comprises when, depending on the adjustment of the viscosity of the polyurethane casting compound 24, an independent, at least partial flow of the liquid polyurethane casting compound 24 also is carried out over the inner face 16, 18 in the course of the introduction operation.
(49) According to the invention, the mold 34 is subsequently closed and the upper mold 14 moved toward the lower mold 13 for this purpose, so that a closed cavity is formed.
(50) Under the action of pressure and temperature, the polyurethane casting compound foams within a predetermined reaction time and forms a cured reinforcement layer 30. The volume of the cured reinforcement layer 30 is considerably greater than the volume of the introduced polyurethane casting compound 24.
(51) Preferably, foaming and curing are carried out with the mold closed.
(52)
(53) The detailed representation according to
(54) The structure 19 can extend with its edge region 37 up to near the edge region 38 of the deep-drawn film 12.
(55) On the other hand, the invention also comprises embodiments in which large distances lie between the edge region 38 of the deep-drawn film 12 and the edge region 37 of the structure 19 containing solar cells 32.
(56) As shown in
(57) The layer structure of the finished panel 10 according to
(58) The reinforcement layer 30 stiffens the panel as a whole, so that this is configured to be completely rigid and can be used in a conventional manner, such as a vehicle part, despite the large width B and the large length, not shown, L and the very small total wall thickness GW.
(59) According to a variant of the invention, which is illustrated in
(60) The barrier layer 27 can advantageously serve to avoid a view by an observer of the reinforcement layer 30 from the outer side of the finished made panel 10. Therefore, no structures of the reinforcement layer 30 can be seen on the surface.
(61) In particular, when, as shown in the embodiment of
(62) According to a further advantageous embodiment of the invention, as shown in
(63) In a further embodiment, not shown, the layer structure of the panel 10 comprises an in-mold-paint layer 28 and additionally a barrier layer 27. Such an embodiment is shown in
(64) According to a further embodiment of the invention, it is now explained as seen in
(65)
(66) It is clear to the person skilled in the art that the electromagnetic radiation obtained by the solar cells 32 has to be led away via lines 26a, 26b after conversion into electrical energy. Connection lines 26a, 26b are provided for this purpose that can be connected in a known manner to the solar cell 32 or the solar cells 32. In order to enable the connections from the interior of the vehicle or from the motor compartment or trunk, it is advantageously provided that a channel 31 is provided in the reinforcement layer 30, which channel allows passage of at least sections of the electrical lines 26a, 26b. This makes it possible to provide the connections on the inner face the panel 10, for example, in the region of the interior of the vehicle or in the region of the motor compartment of the vehicle or the trunk of the vehicle.
(67) The arrangement of the channel 31 in the reinforcement layer 30 can be carried out after the manufacture of the reinforcement layer 30. Alternatively, corresponding inserts can also be provided in the manufacturing of the reinforcement layer.
(68) Alternatively, it can be provided that the electrical lines are already mounted after the mounting of the structure 19 on the deep-drawn film 12, and can be surrounded with foam with the introduction of the liquid polyurethane casting compound 24 and the curing to a reinforcement layer 30.
(69) Also, the channel 31 can be configured as a type of receptacle to the plug, a socket or a connecting element, for example, in the manner of a connector.
(70) As shown in the embodiment of
(71) This variant is, for example, advantageous when attachments are arranged on the outer side of the panel 10 in order to store electrical energy received from the structure 19 in the attachments or to forward from the attachments or in order to provide supply electricity to electrical consumers arranged on the attachments.
(72) In the following, a family of second variants of the invention is explained based on the embodiments of
(73) These variants fall back to methods according to claim 1, having the feature groups j) and k).
(74) Reference is first made to
(75)
(76) The sum of the foamed granular particles 42a, 42b, 42c constitutes the granular particle foam mass 43 used as starting material for the method according to the invention.
(77) As shown in
(78) Subsequently, the mold 34 is closed, wherein the upper mold 14 is moved toward the lower mold 13. With the mold closed, which is tempered by a heating 48, the foamed granular particles 42, 42b, 42c can be baked or sintered to each other. The baking of the granular particle foam mass 43 is carried out under the influence of temperature and/or pressure. The mold 34 can in particular be subject to thermal cycling:
(79) While a higher temperature, in particular above the melting point of the granular particle foam mass 43 is provided in order to perform the process of baking or sintering of the foamed granular particles 42a, 42b, 42c, the mold 34 is either not further heated or cooled (possibly also by a separate cooling device) after a prescribed cycle time, in order to reach a temperature below the melting point of the granular particle foam mass 43.
(80) The cured reinforcement layer 30 formed in this way is provided in this respect by a cured particle foam mass 46.
(81) In the course of baking the foamed particles 42a, 42b, 42c to each other, the particle foam mass also forms a solid connection to the deep-drawn film 12 and to the structure 19 containing the solar cells.
(82) After opening the mold 34, according to
(83) In order to avoid repetition, reference is made to the above statements regarding the previous embodiments of
(84) In particular, it is noted that a barrier coat layer 27 and/or a mold-paint layer 28, as is not illustrated in the drawings of the embodiment according to
(85) The invention further comprises when the foamed granular particles 42a, 42b, 42c that form the granular particle foam mass 43, are converted from a prefoamed state into a final foamed state in the course of the step of baking in the mold 34, and thus the step of baking brings with it an increase in volume of the foamed granular particles 42a, 42b, 42c from a pre-foamed state to a final foamed state.
(86) The invention comprises when foamable plastics are used to provide the granular particle foam mass, which are introduced into the mold 34 in a finally foamed state, and thus the step of baking is carried out without volume change of the granular particles 42a, 42b, 42c.
(87) Finally, the invention also comprises when a volume reduction of the foamed granular particles 42a, 42b, 42c is carried out in the course of baking as a result of the pressure effect and/or the effect of temperature in the closed mold 34.
(88) Referring to
(89) The invention further comprises an embodiment which provides that the mold 34 is overloaded, that is, an amount of granular particle foam mass is introduced into the cavity 33 of the mold 34, whose volume exceeds the volume of the cavity 33. In the case of a mold closing in the course of the step of baking the granular particles 42a, 42b, 42c, the volume of the granular particles 42a, 42b, 42c can be reduced.
(90) With regard to the embodiment of