US 11,890,793 B2
Assembling fiber-reinforced foams
Robert Stein, Ludwigshafen am Rhein (DE); Holger Ruckdaeschel, Ludwigshafen am Rhein (DE); Rene Arbter, Ludwigshafen am Rhein (DE); Tim Diehlmann, Ludwigshafen am Rhein (DE); Gregor Daun, Ludwigshafen am Rhein (DE); and Marc Claude Martin, Lemfoerde (DE)
Assigned to BASF SE, Ludwigshafen am Rhein (DE)
Appl. No. 16/303,447
Filed by BASF SE, Ludwigshafen am Rhein (DE)
PCT Filed May 17, 2017, PCT No. PCT/EP2017/061888
§ 371(c)(1), (2) Date Nov. 20, 2018,
PCT Pub. No. WO2017/202671, PCT Pub. Date Nov. 30, 2017.
Claims priority of application No. 16171416 (EP), filed on May 25, 2016.
Prior Publication US 2020/0331179 A1, Oct. 22, 2020
Int. Cl. B29C 44/50 (2006.01); B29C 44/54 (2006.01); B29C 70/08 (2006.01); B29C 44/56 (2006.01); F03D 1/06 (2006.01); B29C 44/00 (2006.01); B29K 105/04 (2006.01); B29K 105/12 (2006.01); B29L 31/08 (2006.01)
CPC B29C 44/5627 (2013.01) [B29C 44/50 (2013.01); B29C 44/54 (2013.01); B29C 70/086 (2013.01); F03D 1/0675 (2013.01); B29K 2105/04 (2013.01); B29K 2105/12 (2013.01); B29L 2031/085 (2013.01)] 18 Claims
OG exemplary drawing
 
1. A process for converting a molding comprising the following steps a) and b):a) providing a molding comprising a foam and at least one fiber (F), wherein the fiber (F) is with a fiber region (FB2) located inside the molding and surrounded by the foam, b) at least partially dividing the molding at least once, wherein at least one fiber (F) is completely divided to obtain a converted molding, wherein in step a) the molding is provided when at least one fiber (F) is partially introduced into the foam with a result that the fiber (F) is with the fiber region (FB2) located inside the molding and surrounded by the foam while a fiber region (FBI) 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 and the fiber region (FB1) and/or the fiber region (FB3) are then optionally removed, wherein partial introduction is optionally effected by steps a1) to a6): a1) optionally applying at least one layer (S2) and optionally applying at least one carrier layer (TS) to at least one side of the foam, a2) producing one hole per fiber (F) in the foam and optionally in the layer (S2) and optionally in the carrier layer (TS), wherein the hole extends from a first side to a second side of the foam and optionally through the layer (S2) and optionally through the carrier layer (TS), a3) providing at least one fiber (F) on the second side of the foam, a4) passing a needle from the first side of the foam through the hole to the second side of the foam and optionally passing the needle through the layer (S2) and optionally passing the needle through the carrier layer (TS), a5) securing at least one fiber (F) to the needle on the second side of the foam and a6) returning the needle along with the fiber (F) through the hole, so that the fiber (F) is with the fiber region (FB2) located inside the molding and surrounded by the foam while the fiber region (FB1) of the fiber (F) projects from a first side of the molding or optionally from the layer (S2) or optionally from the carrier layer (TS) and the fiber region (FB3) of the fiber (F) projects from a second side of the molding, wherein the at least partial dividing of the molding in step b) is effected with a cutting tool wherein the at least partial dividing of the molding in step b) is effected without material removal-, wherein the fiber region (FB 1) and the fiber region (FB3) each independently of one another account for 0.1% to 45% and the fiber region (FB2) accounts for 10% to 99.8% of the total length of a fiber (F) in step a).