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US-20260124827-A1 - SHAPED PART FOR MANUFACTURING PIECES OF FURNITURE, HAVING INCREASED STABILITY DUE TO ALUMINUM PARTICLES HAVING A LIMITED WEIGHT, PROCESS FOR MANUFACTURING SAID SHAPED PART, AND USE

US20260124827A1US 20260124827 A1US20260124827 A1US 20260124827A1US-20260124827-A1

Abstract

A shaped part is disclosed that includes a polyurethane piece and two outer layers. The shaped part is by its structure suitable for the production of pieces of furniture and, because of the composition of the polyurethane piece using aluminum particles having a limited weight, has increased stability with respect to the customary prior art shaped parts used in the production of pieces of furniture. Also disclosed is a method for the production of the shaped part, the use of the shaped part for the production of pieces of furniture, and the pieces of furniture produced from the shaped part.

Inventors

  • Maximilian Kara
  • Martin Krauss
  • Andreas SCHÖHL

Assignees

  • PUREN GMBH

Dates

Publication Date
20260507
Application Date
20231114
Priority Date
20221115

Claims (17)

  1. 1 . A shaped part for the production of furniture, comprising an inner layer that consists of a polyurethane piece, and two outer layers, and between the outer layers and the inner layer respectively one adhesive layer, with a further adhesive layer on the other side of the polyurethane piece, wherein the polyurethane piece of the inner layer consists of chopped and compressed shreds of polyurethane material, mixed with aluminum particles and a binder, and has a density of 400-700 kg/m 3 , and the outer layers have a layer thickness of 0.10-4.00 mm, and the aluminum particles have a weight of 0.0005 to 2.00 g, and the adhesive layers have an application quantity of 40 to 600 g/m 2 .
  2. 2 . The shaped part according to claim 1 , wherein the outer layer is made of aluminum or of stone veneer.
  3. 3 . The shaped part according to claim 1 , wherein the material which the outer layer consists of is selected from high-pressure pressed laminate, continuous-pressed laminate, carbon fiber, resin-bound textiles, concrete, mineral-bound materials, ceramic materials, glasses, metals, weathering-resistant synthetic materials or precious woods.
  4. 4 . The shaped part according to claim 1 , wherein the aluminum particles are aluminum shreds having a weight of 0.001 to 0.5 g.
  5. 5 . The shaped part according to claim 1 , wherein the adhesive layer is made of a 1 K-PUR prepolymer.
  6. 6 . The shaped part according to claim 1 , wherein the adhesive layer is constructed of an acrylate adhesive, of an in its initial state solvent-containing adhesive, of a dispersion adhesive or of a two-component adhesive.
  7. 7 . The shaped part according to claim 1 , wherein the shaped part is planar and has a panel shape.
  8. 8 . The shaped part according to claim 1 , wherein the polyurethane piece of the inner layer has a density of 550-660 kg/m 3 .
  9. 9 . The shaped part according to claim 1 , wherein the outer layer is varnished with a polyester varnishing, having a layer thickness of 10-25 μm, as the outermost layer.
  10. 10 . A method for the production of a shaped part according to claim 1 , comprising the method steps of chopping a polyurethane foam in a chopper to produce polyurethane shreds, and adding a binder to the polyurethane shreds and mixing, such that a mixture is created, and compressing the resulting mixture to form a polyurethane piece and applying an adhesive layer onto at least one side of the polyurethane piece and a further adhesive layer onto the other side of the polyurethane piece and pressing outer layers having a layer thickness of 0.10-4.00 mm, onto the side of the polyurethane piece on which the adhesive layers have been applied, wherein aluminum particles, having a weight of 0.0005 to 2.00 g, are added to the polyurethane shreds before the compression, and the adhesive layers are applied with an application quantity of 40 g/m 2 to 600 g/m 2 onto the at least one side of the polyurethane piece and the compression for forming a polyurethane piece is carried out with such a pressure and for such a duration that after the compression the polyurethane piece has a density of 400-700 kg/m 3 .
  11. 11 . The method for the production of a shaped part according to claim 10 , wherein stone veneer is pressed on as an outer layer, wherein the stone veneer is obtained by applying a resin onto stone material, applying glass fibers onto the applied resin and removing the glass fibers by hand, and the removed glass fibers with the stone material are pressed on as a stone veneer onto the side of the polyurethane piece which the adhesive layer has been applied onto.
  12. 12 . The method for the production of a shaped part according to claim 10 , wherein the material which the outer layer consists of is selected from high-pressure pressed laminate, continuous-pressed laminate, carbon fiber, resin-bound textiles, concrete, mineral-bound materials, ceramic materials, glasses, metals, weathering-resistant synthetic materials or precious woods.
  13. 13 . The method for the production of a shaped part according to claim 12 , wherein the high-pressure pressed laminate or the continuous-pressed laminate is produced before it is pressed onto the outer layer by impregnating at least two paper layers with melamine resin or phenolic resin, as a result of which a thermosetting synthetic material is created from the melamine resin or phenolic resin after hardening, and this thermosetting synthetic material is pressed as an outer layer onto the side of the polyurethane piece which the adhesive layer has been applied onto.
  14. 14 . The method for the production of a shaped part according to claim 10 , wherein in order to produce the adhesive layer, an acrylate adhesive, an in its initial state solvent-containing adhesive, which is allowed to dry in order to obtain the adhesive effect, a dispersion adhesive or a two-component adhesive is applied onto the at least one side of the polyurethane piece or the adhesive layer is made of a 1 K-PUR prepolymer.
  15. 15 . A use of a shaped part according to claim 1 for the production of pieces of furniture.
  16. 16 . The use of a shaped part according to claim 15 , wherein the production of the piece of furniture is carried out by drilling a screw thread into the shaped part and screwing at least two shaped parts with each other to form a piece of furniture.
  17. 17 . A piece of furniture, produced from a shaped part according to claim 1 .

Description

CROSS-REFERENCE TO RELATED APPLICATIONS This patent application is a U.S. national stage application of international patent application PCT/EP 2023/081753, filed on Nov. 14, 2023, which is based on and claims priority to European patent application EP 22207508.7, filed on Nov. 15, 2022, the contents of which are incorporated herein by reference. FIELD The invention concerns a shaped part which is composed of a polyurethane piece and two outer layers and which, due to its structure, is suitable for the manufacturing of pieces of furniture and, due to the composition of the polyurethane piece and its production by aluminum particles of a limited weight, has an increased stability compared to conventional shaped parts from the prior art which are used in the production of pieces of furniture. The invention also concerns a method for the production of the shaped part and the use of the shaped part for the production of pieces of furniture and the pieces of furniture produced therefrom. BACKGROUND Pieces of furniture have long been known in human history and can be produced from a variety of materials. Aluminum has proven to be very suitable for pieces of furniture because it has a low specific weight and a good mechanical stability. It is therefore possible to produce pieces of furniture which are easily portable and are also durable and have some load capacity. Moreover, aluminum is resistant in air and can be treated in such a way that it has a glossy and visually attractive surface. Herein the aluminum is usually provided as pipes or tubes, from which in turn the load-bearing frames of the pieces of furniture are produced. Depending on the desired construction of the respective piece of furniture, walls or wall pieces may also be produced from aluminum, for example in the form of panels. In principle, however, all materials are suitable for the production of pieces of furniture, wherein those materials which have a low specific weight and a good mechanical stability are preferred. In the production of the pieces of furniture, the problem comes up that the parts intended for the production of the piece of furniture must be fastened with respect to one another. In the mutual fastening of the parts, screw connections are very often used. These have the advantage of being releasable and may moreover be provided for the desired purpose, for example such that they have a certain screw depth depending on the desired fastening strength. However, the aluminum structure is often less suitable for screw threads because it does not have a sufficient thickness and many material parts intended for the production of pieces of furniture are hollow. For this reason, solutions have been proposed in the prior art which provide the inner hollow space of the material parts intended for the production of pieces of furniture with fillers, said fillers making the weight of pieces of furniture increase only insignificantly, but filling the hollow spaces with solid material for improved mechanical strength. Document CN102242560A describes a matted composite material, made of an aluminum-plastic composite material which consists in succession of a matted aluminum plate, a first polymer binder film, an inner polyurethane layer, a polymer adhesive film and a further aluminum plate with a total of five layers. This composite material matted on one side is in particular used for the production of high-end quality pieces of furniture, for example in indoor spaces and in automobiles. The document does not give any indications regarding the construction of the pieces of furniture themselves and also not regarding the mechanical strength of the described composite material. Document EP2796258A2 describes a two-dimensional electrical surface conductor with an insulating layer, comprising a 5 mm thickness layer of polyurethane foam, two electrically conductive aluminum foils, two layers of a 5 mm thickness natural cork agglomerate, furthermore LED light-emitting diodes with electrodes of different lengths which have at their ends an epoxy varnish layer for insulation, and an electric power source. By the cork layer, the surface conductor offers an insulating and at the same time mechanically flexible inner layer for the installation of electrical components for the production of an electrical component having an electrically conductive surface. The document also mentions the possible production of pieces of furniture from the two-dimensional electrical surface conductor. The document likewise does not give any indications regarding the construction of the pieces of furniture themselves and also not regarding the mechanical strength of the described two-dimensional electrical surface conductor. Document DE202016106033U1 describes a panel with a core made of an extruded rigid-foam material, which is on at least one surface side provided with a cover layer made of a high-pressure laminated material (HPL), wherein the panel has on its end faces a