EP1115893A1

EP1115893A1 - Method for producing shaped bodies

Info

Publication number: EP1115893A1
Application number: EP99969126A
Authority: EP
Inventors: Hans-Wilhelm Bergmann; Peter ÜBELMESSER
Original assignee: Atz-Evus Applikations- und Technik-Zentrum fur Energieverfahren- umwelt- und Stromungstechnik; Frenzelit Werke GmbH
Current assignee: Atz-Evus Applikations- und Technik-Zentrum fur Energieverfahren- umwelt- und Stromungstechnik; Frenzelit Werke GmbH
Priority date: 1998-09-14
Filing date: 1999-09-14
Publication date: 2001-07-18
Anticipated expiration: 2019-09-14
Also published as: ES2178501T3; EP1115893B1; AU5978299A; ATE219161T1; CZ2001855A3; DK1115893T3; WO2000015860A1; EP1115893B2; PT1115893E

Abstract

The invention relates to a method for producing shaped bodies which have an appropriate rigidity and which are comprised of flexible textile substrates. The shaped bodies can be joined to other shaped bodies with a non-positive, material, and positive fit. According to the inventive method, a textile substrate is impregnated by thermally spraying melted, metallic and optionally ceramic particles on at least one textile scrim fabric web, interwoven fabric, knitted fabric or nonwoven fabric. The textile substrate is impregnated in such a way that the melted, sprayed-on, metallic and optionally ceramic particles are intimately bound in a partial manner to the fabric fibers, and the particles are intimately bound to one another in a partial manner. The rigidity is obtained by interweaving the fibers. The flexible textile substrates are essentially comprised of fibrous materials or fibers which do not contain asbestos or inorganic fibrous materials with fiber lengths having a length > 5 mu m, a diameter < 3 mu m and a length-to-diameter ratio of > 3:1. The invention also relates to shaped bodies which have an appropriate rigidity and which can be obtained according to the inventive method.

Description

Title: Process for the production of molded bodies

description

The present invention relates to a new molding process, i. H. Three-dimensional molded articles with functional stiffness are produced from flexible textile substrates by coating shaped fabrics.

The flexible textile substrates are stiffened by thermal spraying, in particular by wire flame spraying and / or arc spraying and / or high-speed spraying (HVOF) and / or by plasma spraying. The functional rigidity of the molded part can be achieved by different application thicknesses or quantities. It is essential that the molded body produced by means of the usual connection techniques such. B. welding, screws, etc. can be reconnected with other moldings.

The present invention further relates to an asbestos-free or other inorganic fibrous substances, with fiber lengths of> 5 microns, a diameter of <3 microns, a length / diameter ratio of 3: 1, free flat composite material, that is, a molded body consisting of at least a first layer consists of a textile lattice fabric, mesh, knitted fabric, knitted fabric or fleece and at least one second layer made of metal and / or ceramic applied to this first layer. The molded body is characterized by a functional stiffness and is mainly used as a soft tissue compensator, as a smoke apron, as a fire baffle molding (fire baffle block), as a molded body for thermal shielding in the automotive industry, as a bumper or as a load-bearing component in lightweight construction. Asbestos and all inorganic fibers (artificial mineral fibers), ie also ceramic fibers within a certain fiber distribution spectrum with certain fiber lengths (> 5 μm length, diameter <_3 μm, length / diameter = 3: 1), have health-endangering effects. In particular, the harmful effects of asbestos have been known for a long time. With ceramic fibers, it is also known that these are respirable and are therefore classified as a K2 hazardous substance (carcinogenic potential) according to the new EU legislation (cf. 3rd Regulation amending the GefStVO and TRGS 905). Therefore, new materials or composite molded parts or parts that can be produced therefrom should be made available without using the fibers mentioned above, if possible. Areas of application for such materials (without the health-endangering fibers) are, for example, the production of flue gas expansion joints, fire baffles, moldings for the automotive industry.

Glass fiber fabrics and / or glass nonwovens come into consideration as a possible substitute material. Such uncoated glass fiber fabrics, however, have no flame deflection properties due to the open-pore structure, but rather flame absorption properties. In addition, such fabrics are not dimensionally stable, which leads to erosion and erosion at high hot air speeds.

In boiler systems, so-called fire baffles made of other materials are currently still being used on the opposite side of the burner, which are responsible for the flame deflection in the next train and thus the better use of heat by the energy sources used.

Classically, however, products are required for this purpose that have a high temperature resistance of> 1000 ° C, but also a deflecting effect and no absorbing effect for open flames. In addition, such products require a high degree of insulation, but also dimensional stability.

Products of this type typically consist of, for example, vacuum-formed ceramic fiber composite materials. Such products are currently made with ceramic fibers manufactured that are respirable and therefore must be classified as a K2 hazardous substance (carcinogenic potential).

For the manufacture of flue gas expansion joints, flexible, textile products are required that can compensate for the corresponding angular, torsional and axial movements of flue gas lines.

For expansion joints of this type, products that are flame-retardant but better, but non-flammable, and at the same time have a high level of smoke-tightness both at room temperature and in the event of a fire, are required in accordance with the DIN 18232 standard applicable here.

Up to now, such compensators could only be realized with the help of a complex multilayer structure. Here, the high temperature (according to the ETK according to DIN 4102) is normally broken down or isolated over several layers of an insulation material until appropriate gas-tight but low-temperature-resistant polymer membranes can ensure the low leakage.

Such a fabric-reinforced elastomer compensator is known from DE 38 20 922 C2. This compensator contains fluororubber as an elastomer component and as reinforcement a textile mesh made of aramid fiber and / or E-glass fiber in combination with the fluororubber elastomer component.

The automotive industry is also looking for new, lighter materials instead of rigid sheet metal parts for certain purposes. In this context, it can generally be stated that there is, however, a trend towards more powerful engines, but at the same time towards a more compact design. Furthermore, the proportion of electronic assemblies in motor vehicles is increasing by leaps and bounds. This development particularly affects the engine compartment of motor vehicles. Here, temperature-unstable materials such as rubber buffers, rubber bearings etc. and vibration dampers are moving ever closer to the engine block or near the exhaust system. Temperatures prevail here, which in some cases can exceed 1000 ° C. To noticeably age or destroy these tem- To prevent temperature sensitive products, these products must be protected from the heat. The same applies to electrical or electronic components, such as

Harnesses.

Rigid sheet metal parts are currently used for the above-mentioned purposes, which are deep-drawn for insulation purposes as a sandwich sheet with an insulation insert. Polymer-coated glass fabrics or laminated glass fabrics are often used as cable insulation.

Rigid sheet metal parts offer the advantage that due to the dimensional accuracy of rigid molded parts, movable components or other assemblies can be safely guided past. On the other hand, such shields are complex to manufacture due to the corresponding forming processes and are comparatively difficult. Due to the vibration behavior, they also offer the risk of touching neighboring components and thus the problem of noise. In many applications, however, are also, for example, precisely from a vibration engineering perspective, such as Fatigue, vibration and breakage of sheet metal parts, rigid components not a suitable material. In addition, a later revision or assembly of adjacent components can be restricted or prevented by a rigid component.

However, it has long been known from the prior art to provide certain carrier materials with layers of ceramic material (oxide or non-oxide ceramic layers). Furthermore, it is known to provide textiles with adhesive metal pads. For example, from DE-OS 26 59 625 and DE-PS 31 27 505 a method for metallizing textiles is known. DE-OS 26 59 625 is about the metallization of a cut textile piece, which is carried out by means of an electrochemical process. The metallized textile piece is then impregnated with synthetic resin together with other non-metallized textile pieces of the same cut and pressed together to form a stack in order to prevent the rigid metal layer from breaking or tearing during bending. The whole thing serves primarily printed circuits. Furthermore, it is known Wear protection layers on glass fiber reinforced plastic materials, such as. B. rollers, tubes and flat parts by means of thermal spraying.

In many cases, polymer-coated textile fabrics show a lack of temperature persistence and the problem of the flammability of the applied coating.

Coatings are therefore known from the prior art, which are basically carried out with polymeric binder or basic systems. However, these often have disadvantages for certain areas of application. The organic content of accompanying substances leads to loss of ignition, smoke and odors when exposed to temperature. Furthermore, there is a lack of permanence of the product when exposed to temperature. In principle, these materials cannot be classified as non-flammable (AI) in DIN 4102.

Furthermore, the plasma spray coating of fabrics for use in electrical engineering is known. Corresponding methods and applications are described in US-A-4,357,387, US-A-4,713,284 and DE-U-90 12 342.

It is also e.g. known from WO 96/03277 to produce protective clothing from fabrics by applying a layer of a ceramic material to a carrier material by means of plasma spraying.

The present invention is therefore based on the object of providing a new process for the production of moldings with functional stiffness from flexible textile substrates. The flexible textile substrates are to be made from fibers classified as harmless to health. These new moldings are said to be able to be used in various fields of application, such as in the motor vehicle industry, ie in vehicle construction or in robotics, and to replace the moldings which have been customary to date. This object is achieved according to the invention by a process for the production of moldings with functional stiffness from flexible textile substrates, the moldings being non-positively, materially and positively connectable to other moldings, with thermal spraying of molten, metallic and possibly ceramic particles onto at least one Textile lattice fabric web, a mesh, knitted fabric, knitted fabric or a nonwoven soaked this textile substrate, so that an intimate connection of the metallic and possibly ceramic particles sprayed on in the molten state is produced partly with the fabric fibers and partly with one another an intimate connection and by integrating the fibers, a stiffness is achieved, the flexible, textile substrates essentially consisting of fibrous substances or fibers made of asbestos or inorganic fibrous substances with fiber lengths with a length> 5 μm, a diameter <3 μm and a length e-to-diameter ratio of> 3: 1 are free (see claim 1).

Furthermore, this object is achieved by the molded body with functional rigidity according to claim 10.

Advantageous embodiments of the invention are contained in the subclaims.

Surprisingly, the inventors have found that flexible textile substrates can be converted into moldings with functional stiffness by coating woven fabrics. This is due to the fact that the metallic and possibly ceramic particles sprayed on in the molten state enter into an intimate connection partly with the fabric fibers and partly with each other. This creates a layer or a shaped body which is relatively flexible and can therefore be deformed within wide limits without the risk of crack formation. The molded body according to the invention can be non-positively, materially and positively with other molded bodies by conventional connection techniques, such as. B. welding, screwing, etc. are connected. This is achieved by partially applying thicker layers around the joints. This composite material according to the invention or the molded body consists of at least a first layer of a textile lattice fabric, mesh, knitted fabric, knitted fabric or fleece made of aramid fibers and / or E-glass fibers and / or silicon dioxide-rich glass fibers and / or carbon fibers and at least one on this first layer by means of plasma spraying, by means of flame spraying and / or plasma coating applied second layer of metal and / or ceramic.

The flat composite material according to the invention or the shaped body can either be a soft material compensator, a fire impact molded part, a shaped body for the motor vehicle industry or a load-bearing component in lightweight construction. Examples of moldings in the automotive industry are e.g. Heat shielding parts in the area of the engine block of a motor vehicle or bumper. In addition, cable harness insulation and lever arms are considered as areas of application in robot technology. The composite structures according to the invention can also be used as stabilizing components in vehicle construction. By partially thickening the coating, welded connections or other types of connections such as screw connections can be made at certain points. Furthermore, the molding can be adjusted in terms of rigidity by partially thickening the coating. Through a continuous transition from metal to textile, according to the invention, a gradient material with correspondingly different properties from soft, flexible to stiff, dimensionally stable is created. The coating of fabrics also prevents fraying and the displaceability of the glass fabric fibers.

The first layer of the textile substrate can consist of one or more layers. In principle, all textile fibers, in particular aramid fibers and / or E-glass fibers and / or silicon dioxide-rich glass fibers and / or carbon fibers, can be considered as material here. The silicon dioxide-rich glass fibers have an SiO ₂ content of over 95%. Textiles made from silicon dioxide-rich glass fibers are therefore very temperature-stable, ie up to 1100 ° C.

Nonwovens, ie so-called needle mats, can currently be produced up to thicknesses of 75 mm with densities of <200 kg / cm ³ . Due to the open-pore structure, the textile fabrics used as “substrate” according to the invention have no flame deflection properties, but rather the opposite of flame absorption properties. Therefore, according to the invention, a coating of metal and / or ceramic is applied here by means of thermal spraying, in particular wire flame spraying, arc spraying, plasma spraying Coating, in particular made of aluminum or high-tempered steel, eg V4-A steel or chrome-nickel alloys, has a stabilizing effect on the final shape at the same time. However, this depends on the thickness of the metal coating, which can range from 0.1 to 5 mm, in particular 0.1 to 1.4 mm.

The coating prevents the erosion of the fibers and their removal at the high hot air speeds that occur here. In addition, the coating reverses the flame and stabilizes the shape.

According to one embodiment of the method according to the invention, a textile web is used as the substrate. This web has already been made by means of thermal spraying, i.e. in particular with wire flame spraying and / or arc spraying and / or plasma spraying with a layer of metal such as e.g. Aluminum. A flat blank is then produced from this coated web. This flat blank can then in turn be coated with metal on the back. It is advantageous if the cut edges are also coated with metal. According to the invention, it is therefore possible to coat the textile fabric web continuously or discontinuously or as a blank or as a die cut.

According to the invention, a molded body, such as, for example: a soft material compensator, a fire impact molded part or a molded part for the motor vehicle industry, can thus be produced.

According to the invention, it is therefore possible for the first time to provide the connection of high-temperature-resistant glass and special glass (silica glass) fabrics or nonwovens, ie textile surface products, with an inorganic film-forming coating that a practical product, for example: a high-temperature compensator, can be produced therefrom, and / or that a molding is produced directly by the coating.

The flat composite material according to the invention or the molded body can, as already explained above, be a soft material compensator, a fire impact molded part or a molded part for thermal shielding in the motor vehicle industry.

Molded parts for thermal shielding

A suitable drapable fabric was drawn into a three-dimensional structure and fixed by vacuum deep drawing.

With the help of the thermal spraying process of aluminum, for example, the fabric structure is fixed by uniformly applying a thin coating layer of approx. 75 g / m ² aluminum. The coating process also makes it possible to locally increase the quantity of the coating. In principle, the process control enables this support thickness to be built up to several centimeters. This is used in order to achieve stiffening up to absolute dimensional stability and hardness in places that are statically important for the molded body. This also applies to positions in the molded body where a movable component must be guided safely and functionally. At the same time, a coating quantity can be selected at other points on the molded body that meets the requirements of absolute fiber integration and thermal shielding and tightness in such a way that the textile and flexible character of this section is nevertheless retained. The transition zones between soft, textile, flexible zones and shaping and shape-stabilizing, hard zones of the molded body correspond to a continuous material transfer in the sense of a gradient material.

An important advantage of the manufacturing process is that the classic fastening technology by means of screws can be strengthened by the local reinforcement of the screw bushing to such an extent that a secure screw fastening without additional aids such as eyelets can be realized. This also happens through the gradual application of the coating layer. In extreme cases, a sufficiently high metal layer on the textile carrier can also be used to secure the textile gradient material using welds or spot welding.

Gradient materials can not only be created in such a way that a gradient is achieved with regard to the amount of support, but also when using the coating materials. In the specific case, a pre-coating with another, more ductile metal z. As zinc, on the one hand, the adhesion of the coating on the textile backing, on the other hand, the brittleness of the coating can be influenced by z. B. to be able to design tight radii within a molded part. Precoatings are usually used here in the application quantity of approx. 50 g / m ² . Of course, these precoatings can also be applied locally so that they can then be coated with an appropriate top layer, e.g. B. Aluminum to be sealed. Thus, the term gradient material refers not only to different coating quantities but also to different coating materials that can be applied continuously and functionally.

The advantages of such a molded part in the specific application as a shielding part lie in the substantially more favorable sound or acoustic behavior with the same heat shielding properties. It is no longer essential to maintain the otherwise usual large minimum distances from classic sandwich panels of body parts. This leads to flexibility in the design of appropriate shielding parts, especially in large spaces. The weight reduction compared to the previous materials is also considerable and, as in the specific case, can be 50%. Another advantage of the moldings according to the invention is that they are impermeable to moisture.

However, thermal shielding does not always have to have the character of a preformed component. Often, simply by choosing the attachment points one Shape realized. Such solutions have traditionally already been implemented with the textiles described above with a polymer coating. In addition to the disadvantages mentioned, the lack of temperature persistence of the coating and the flammability, such products also have disadvantages in terms of fastening technology and heat radiation (IR emission). In the specific case, the screw bushings must be secured with eyelets, because if the temperature is high, the pull-out strength achieved by the coating in the fastening points is completely lost due to the destruction of the coating. The molded parts according to the invention have temperature-permeable coatings and can additionally be reinforced in the fastening points (gradient coating). They therefore offer absolute security against tearing out. The IR emission coefficient, which is approximately halved compared to polymeric coating systems, also leads to an equally halved energy input due to the heat radiation component in the units to be protected. In the case of the relatively simple geometric shapes described in connection with the invention, the molded body according to the invention can be produced by a coating layer of approximately 300 g / m ² as a cold-deformable material, which in turn offers easier assembly and stability due to the preformability.

The invention will now be described in more detail with reference to the following examples and figures, but without restricting them to them.

Show it:

Fig. La is a schematic plan view of a molded body according to the invention, namely a smoke apron;

1b shows a cross section of a smoke apron according to the invention;

Fig. Lc shows a longitudinal section of a smoke apron according to the invention;

2a shows a schematic top view of a filter insert according to the invention; 2b shows a cross section of a filter insert according to the invention;

3 shows a schematic top view of a heat shielding part according to the invention;

4a shows a section of the heat shielding part according to line A-A according to FIG. 3;

4b shows a section of the heat shielding part according to line B-B according to FIG. 3;

4c shows a section of the heat shielding part according to line C-C according to FIG. 3;

4d shows a section of the heat shielding part according to line D-D according to FIG. 3;

5 shows a flue gas compensator according to the invention; and

Fig. 6 shows a load-bearing component in the lightweight component (lever arm in robot technology).

example 1

Production of a flue gas compensator according to the invention

A plain-weave glass fabric isoGLAS ^® fabric type 1115 was continuously coated in a width of 33 cm on both sides with elemental aluminum using the wire flame spraying method.

For this purpose, a spray gun was mounted on a controllable traversing device. At the same time, the tissue was moved further in the longitudinal direction.

The distance from the spray head to the fabric is 200 mm. The diameter of the spray cone is 20 mm with very little overspray. In the configuration mentioned here, a coating speed of approx.

30-40 m ² / h per side.

The amount of coating selected here was 150 g / m ² per side. In total, the finished article is approx. 300 g / m ² with a total weight of the finished article of approx. 1400 g / m ² . In general, any amount of aluminum can be applied through several coating passes. Concrete tests on different fabrics and nonwovens show coating layers on one side from 500g / m ² up to approx. 1000g / m ² , which corresponds to a layer thickness of approx. 1.4 mm. With articles of this type, the flexibility decreases; Here, however, a corresponding dimensional stability can be achieved.

With the coating layer of 150g / m ² used here, the temperature-independent low leakage is achieved on the one hand (synonymous with a constant tightness over the application temperature range). On the other hand, despite the coating, you get the necessary flexibility and mobility of the article.

The coating also increases the dimensional stability of the fabric; however, this also results in a significantly improved ability to be assembled. This means in particular an improved cutting possibility without fraying warp or weft threads; At the same time, the cut edges are partially sealed by pressing or squeezing the cut zone with the aluminum applied as a coating.

Classic textile techniques such as sewing can be used as joining techniques. In general, a welded joint should also be considered. The latter possibility can be achieved by the targeted application of a large amount of aluminum at the overlap points or connection points, so that welding of the metal coating is possible using the usual methods of welding aluminum. Example 2

Production of a flue gas compensator according to the invention

For this purpose, a tube made of silicon dioxide-rich glass fibers was pulled onto a rotating metal shaft and attached to it. The process of thermal spraying first applied a uniform, thin layer (approx. 75 g / m ² aluminum to stabilize the hose ⁾ to the hose. Subsequently, a much thicker support was implemented. In the specific case, this was approx. 1.5 cm wall thickness The transition from the thinly coated surface to the end areas was continuous.

This creates a metal composite material in the form of a tube, which is soft, flexible on the inside and can absorb and execute both axial and radial movements. However, the coating layer in the inner part is selected so that sufficient smoke gas tightness is also achieved in the inner part. The textile carrier hose is used to isolate the temperatures transmitted by the hot flue gases and in conjunction with the coating to seal the flue gas. In addition, the textile hose in the intimate material combination of metal and textile ensures the resulting rigidity and stability of the entire part.

In a further work step, the applied material was machined (turned) in the edge areas of the compensator, so that a connecting flange or a connecting sleeve is created.

With the help of this continuous transition from flexible, movable assemblies to rigid and stable zones, the problem of connecting such fiber composite or gradient materials can be solved elegantly. Both screwed, flanged or welded are used as connection techniques

Connections in question.

Example 3

Production of a load-bearing component according to the invention (lightweight construction)

For this purpose, a tube made of p-aramid fibers was pulled over a rotating shaft and coated in the same way as described in Example 2. Here, however, the layer thickness initially applied evenly over the entire width of the hose is more than 400 g / m ² . The end regions are then massively reinforced locally, so that a machining treatment can also be carried out here in a further processing step.

The end product must also be referred to here as a gradient material because of the continuous transition from the inner part of the tube to the outer area. Due to the fiber composite structure of metal and aramid fibers, however, a stable, lightweight structural component is produced, the connection to other components in turn by welding. Flange technology or screws can be solved optimally. The use can e.g. B. as a lever arm in robotics; can be used as a stabilizing component in vehicle construction.

Example 4

Production of a fire impact molded body according to the invention (fire impact stone)

So-called isoTHERM ^® S material, which is temperature stable up to 1100 ° C, was used as the textile fabric. These are silicon dioxide-rich glass fibers with an SiO ₂ content of over 95%. Nonwovens made from isoTHERM ^® S, ie so-called

Needle mats can be produced up to a thickness of 75 mm as very compact sheets.

Since nonwovens of this type have no flame deflection properties due to the open-pore structure, but rather the opposite, flame absorption properties, a solution can only be achieved here by a suitable closed, temperature-stable coating.

The coating must also have a stabilizing effect on the final shape; this coating must also prevent the erosion of fibers and their removal at the high hot air speeds that occur here.

A above-described standard fleece with a thickness of 45 mm and a density of> 200 kg / m ³ was mechanically pressed and punched into the specified shape.

The labile molded part in this way was now clamped vertically.

A thin layer of aluminum, approx. 70 g / m ² , was first applied as the carrier layer using the wire flame spraying process. The wire flame spraying method A1 ₂ 0 ₃ was then sprayed onto the surface prepared in this way. The order quantity in the concrete area is approx. 300-500g / m ² . The distance between the spray nozzle and the fleece is 110 mm. The coating is also achieved very evenly by the traversing movement of the spray gun and the horizontal movement of the spray gun.

This results in the molded part being stabilized by the relatively break-resistant, closed ceramic layer made of Al ₂ O ₃ . Due to the closed surface, very good flame deflection behavior is achieved. Abrasion or erosion of the fibers can also be prevented by the closed, temperature-stable layer. The insulation ability of the product is due to the well-known thermal engineering

Properties of the nonwoven also guaranteed.

Example 5

Production of a smoke apron according to the invention

Smoke aprons made from Mtex- »(trade name from Frenzelit, Germany for technical textiles coated with metals) were made from a V4A wire-reinforced glass fabric.

For this purpose, this fabric was initially evenly coated on both sides with a coating layer of approx. 150-200 g / m ² aluminum. About the fabric width vzw. Subsequently, an approximately 20mm wide strip was coated to a final thickness of 2mm, thus stiffening and stabilizing. This was done in a continuous process, depending on the desired length of the curtain, e.g. B. 2m performed repeatedly in this way. The fabric edges were also reinforced to a width of approx. 20mm up to a coating layer of approx. 400g / m ² .

The result is endless tracks that have a 20mm wide and 2mm thick tape every 2m, before which you can then cut; in addition, these webs have edge reinforcement.

Here too, a molded body with a functional rigidity is produced. Here, the 2mm thick thickening across the fabric width serves to securely fasten the curtains to the upper shaft; the edge reinforcement enables the combination and the joining together of several identical, cut lengths. The fastening techniques available here fall under the structure of non-positive, positive or material. Similar to the products described above, the term gradient material also applies here, due to the smooth transition towards the edge and transverse stiffeners and the basic preservability of the rollability of the textile web, with the advantage that the known, proven rolling devices can be retained.

Such smoke aprons serve vzw. in industrial plants and large halls for the sectioning of large rooms for better removal of the smoke and smoke that occurs in the event of a fire.

Fire protection devices of this type which are common today are either in the form of stable sheet metal ducts or in the form of roller shutters which are only triggered and moved down in the event of a fire. Such roller shutter solutions exist today vzw. from glass fabrics which are additionally polymer-coated for reasons of manageability and assembly. This is accompanied by the known problems such as flame retardancy or even flammability, smoke development of the coating in the event of a fire; and problems with the fastening technology and the stability of the fastening under fire conditions.

These problems are avoided with the system described here. The types of fastening can be designed to be temperature stable and non-flammable; the product is to be classified as non-flammable due to its consistently inorganic structure as AI.

Example 6

Production of a filter insert according to the invention

In the present case, a filtration insert for high-temperature filtration or hot gas filtration was produced.

In the present case, V4A wire-reinforced glass fabrics were used as the carrier fabric Commitment.

Depending on the desired porosity, these are first coated with aluminum evenly over the entire filter surface. 200 g / m ^{2 of} aluminum can be regarded as a typical support quantity in the area of the filter surface for the carrier fabrics used here.

The porosity, or the pore volume, and the pore size distribution can be varied in this method via the parameters of thermal spraying, such as spraying distance and application quantity, etc. Furthermore, these parameters are influenced by the type of weave, the fabric density and the fiber materials.

In the specific case, a substantially higher amount of coating was applied directly after the uniform, homogeneous coating of the filter surface in the edge region. The application thickness in this area is approx. 1.5 mm. On the one hand, these areas fix the free filter surface similar to a frame; on the other hand, this frame enables fastening by screws, rivets; Welding; Soldering. The stiffened frame allows the handling of these filters such. B. insertion into the corresponding filter housing. The resulting finished product thus has the character of a shaped body with areas of functional rigidity. This is generated by locally different coating layers.

This molded body can also be referred to as a gradient material. As already outlined in the previous examples, the gradients can be generated by different metals, as well as by the continuous transition from rigid, rigid structures to softer, in this case permeable areas. Gradient materials are thus created from the point of view of gradually different porosity between the rigid edge areas and the filtration surface. The advantages of such a filtration system for those described above

Areas of application are in the temperature and corrosion resistance of the necessary connecting and connecting elements, in the simplicity of assembly and the

Single substance character of the entire system.

Example 7

Production of a molded body according to the invention for thermal shielding (heat shielding part)

Using the process of thermal spraying (wire flame spraying) of aluminum, the fabric structure is first fixed by uniformly applying a thin coating layer of approx. 75 g / m ² aluminum. The coating process also makes it possible to locally increase the quantity of the coating. In principle, the procedure enables this support thickness to be built up to several centimeters. This is used in order to achieve stiffening up to absolute dimensional stability and hardness in places that are statically important for the molded body. This also applies to positions in the molded body where a movable component must be guided safely and functionally. At the same time, a coating quantity can be selected at other points on the molded body that meets the requirements of absolute fiber integration and thermal shielding and tightness in such a way that the textile and flexible character of this section is nevertheless retained. The transition zones between soft, textile, flexible zones and shaping and shape-stabilizing, hard zones of the molded body correspond to a continuous material transfer in the sense of a gradient material. 3 and 4 show the heat shielding part produced according to the invention. Reference list

1 basic textile material

2 primer layer or basic coating; Metal layer 1

3 top layer of metal; Metal layer 2

4 continuously expiring layer 3 gradient zone

5 local stiffening due to higher metal layers - gradient zone

Claims

claims

1. A process for the production of moldings with functional stiffness from flexible textile substrates, the moldings being non-positively, materially and positively connectable to other moldings, characterized in that by thermal spraying of molten, metallic and possibly ceramic particles onto at least one Textile lattice fabric web, a mesh, knitted fabric, knitted fabric or a nonwoven soaked this textile substrate, so that an intimate connection of the metallic and possibly ceramic particles sprayed on in the molten state is produced partly with the fabric fibers and partly with one another an intimate connection and by incorporating the fibers, a stiffness is achieved, the flexible, textile substrates essentially consisting of fibrous substances or fibers which are composed of asbestos or inorganic fibrous substances with fiber lengths with a length> 5 μm, a diameter <3 μm and a length To-Diameter Ver ratio of> 3: 1 are free.

2. The method according to claim 1, characterized in that a uniform layer thickness of 0.1 to a maximum of 10 mm, in particular from 0.1 to a maximum of 5 mm, is applied continuously by means of thermal spraying.

3. The method according to claim 1, characterized in that locally different layer thicknesses are produced for fastening the molded parts.

4. Process for the production of molded articles with functional stiffness from flexible textile substrates, the molded articles being non-positive, material and positive are connectable with other moldings, characterized in that as textiles

Substrate a textile lattice fabric web, a -braid, -woven fabric, -knitted fabric or a

Fleece selects, the textile substrate of asbestos or inorganic fibrous

Fabrics or fibers with a length> 5 μm, a diameter <3 μm and a

Length-to-diameter ratio of> 3: 1 is free from the web a flat

The blank is cut off or punched out and this blank or this punched out is sprayed by means of thermal spraying of molten metallic and possibly ceramic particles onto at least one surface of the planar blank so that the metallic and possibly ceramic particles sprayed on in the molten state partly with the fabric fibers and partly with one another enter into an intimate connection and stiffness is achieved.

5. The method according to any one of claims 1 to 4, characterized in that the selected textile substrate is pre-coated by uniform spraying from 50 to 100 g / m ² , in particular from 75 g / m ² , so brought into shape and possibly a Makes the final coating.

6. The method according to any one of the preceding claims, characterized in that one achieves a partial thickening of the coating in order to enable connection techniques.

7. The method according to any one of the preceding claims 1 to 6, characterized in that a further layer adjacent to the first layer of textile lattice fabric, mesh, knitted fabric, or knitted fabric or fleece made of natural and / or synthetic fibers is arranged to the first layer , whereby this layer is firmly connected to the first layer and this layer may have a lower temperature stability or have sound insulation properties.

8. The method according to any one of the preceding claims, characterized in that on the back of the at least first layer by means of thermal spraying another layer of metal and possibly ceramic. So that the first layer as

Interlayer acts.

9. The method according to one or more of the preceding claims, characterized in that application quantities of 100 to 500 g / m ^{2 are} applied to the at least one flexible textile substrate.

10. Shaped body with functional rigidity, obtainable according to the method according to any one of the preceding claims 1 to 9.

1 1. Shaped body according to claim 10, characterized in that it contains another layer adjacent to the first layer of textile lattice fabric, mesh, knitted, or knitted or nonwoven made of natural and / or synthetic fibers, this layer being fixed to the first layer is connected and possibly has a lower temperature stability or has sound insulation properties.

12. Shaped body according to one of claims 10 or 11, characterized in that a further layer of metal and possibly ceramic is applied to the back of the at least first layer, so that the first layer acts as an intermediate layer.

13. Shaped body according to one or more of the preceding claims, characterized in that the at least one metallized layer and possibly the ceramic layer have different materials and optionally have a different porosity.

14. Molded body according to one of claims 10 to 13, characterized in that the metallic or ceramic particles made of Al, Al alloys, Cu alloys, Cr-Ni alloy, titanium., V4-A steel, Mb, Al _2nd O ₃ , Cr ₂ O ₃ , TiO ₂ , TBC-ZrO ₂ , ZrO ₂ -CaO, or mixed oxides of the aforementioned non-metals.

15. Molded body according to any one of claims 10 to 14, characterized in that the at least one metal and / or ceramic layer has a substantially uniform layer thickness of 0.1 to 5 mm, in particular 0.1 to 1.4 mm.

16. molded article according to any one of the preceding claims 10 to 15, characterized in that the at least one metal and / or ceramic layer has locally different layer thicknesses.

17. Molded body according to one of claims 10 to 16, characterized in that the layer thickness of the at least one layer of textile lattice fabric, mesh, knitted fabric, or non-woven fabric has a thickness of 0.1 mm to 80 mm.

18. Molded body according to one of the preceding claims, characterized in that the E-glass fiber or silicon dioxide-rich glass fiber fabric consists of textured or non-textured glass filaments or glass staple yarns and can optionally be reinforced with V4A steel wire.

19. Molded body according to claim 18, characterized in that it has a layer of metal and / or ceramic, in particular aluminum, on the cut edges.

20. Molded body according to one or more of the preceding claims, characterized in that it is a soft material compensator, a fire molded part, a molded part for thermal shielding in the motor vehicle industry, a smoke protector, a filter insert or a bumper.