CN101111786A - 背衬织物的成卷材料和衣服带子 - Google Patents

背衬织物的成卷材料和衣服带子 Download PDF

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CN101111786A
CN101111786A CN200680003383.1A CN200680003383A CN101111786A CN 101111786 A CN101111786 A CN 101111786A CN 200680003383 A CN200680003383 A CN 200680003383A CN 101111786 A CN101111786 A CN 101111786A
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prisms
thermoplastic
thermoplastic coating
layers
tissue layer
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杰·索弗特
布鲁克·杰泽克
杰弗·S·斯坦尼
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Reflexite Corp
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Abstract

回射片材(10)包括底层(12)，该底层包含热塑性聚合物。棱镜层(16)放置在底层(12)上。织物层(24)有热塑性涂层(23)在该织物层的一个面上，其中所述热塑性涂层(23)面对棱镜层(16)而且所述底层(12)、棱镜层(16)、热塑性涂层(23)和织物层(24)的一部分附着在一起形成封口。用来形成回射片材的方法包括提供包括热塑性聚合物的底层(12)和把棱镜层(16)放置在膜层(12)上。把一面有热塑性涂层(23)的织物层(24)这样放置使热塑性涂层(23)面对棱镜层(16)。在有足够的热量存在的情况下用模具对底层(12)和织物层(24)加压，使织物上的热塑性涂层(23)和底层(12)把底层(12)的某些部分贴到织物层(24)的热塑性涂层(23)上，借此形成回射结构。

Description

背衬织物的成卷材料和衣服带子
相关申请
这份申请要求2005年1月31日申请的美国专利临时申请第60/648,613号的利益。上述申请的全部教导在此通过引证被并入。
背景技术
回射标志有许多用途，包括交通安全标志。往往这些标志只需要暂时使用，例如，用于前方道路施工或汽车故障停在路边的警告标志。在使用这些标志以前和以后，它们可能需要储存在尽可能紧凑的空间中。这通常需要将这些标志卷起或折叠。
采用已知回射标志的困难之一是它们有用作背衬的塑料片材。虽然塑料片材可能是柔软的而且能卷起，但是该片材可能仍然是比较硬的。
所以，需要更柔软而且能卷得更紧的回射结构。
发明内容
回射片材包括含有热塑性聚合物的底层和织物层。棱镜层被放置在底层上。织物层有在其一面上的热塑性涂层。织物层是这样放置的，以致该热塑性涂层面对棱镜层。底层、棱镜层、热塑性涂层和织物层至少部分地相互贴合以形成封口。
在一个实施方案中，热塑性涂层包括热塑性聚氨酯。
在另一个实施方案中，热塑性涂层包括聚氯乙烯。
用来形成回射片材的方法包括提供在它上面放置了棱镜层并且包含热塑性聚合物的底层。把一面有热塑性涂层的织物层这样放置使该热塑性涂层面对棱镜层。在有充份的热量存在的情况下用模具对底层和织物层加压使织物上的热塑性涂层和底层将底层的某些部分附着到织物层的热塑性涂层上，借此形成回射结构。该热塑性涂层能包括一个热塑性聚氨酯或聚氯乙烯。
本发明的优势是通过使用织物作为背衬材料，提供比只使用塑料片材作为背衬的回射结构更柔软的回射结构。
依照本发明的回射片材结构能用于卷起的交通和道路标志，甚至作为衣服带子。
附图说明
图1是焊接之前本发明的回射结构的一个实施方案的剖视图。
图2是焊接之后本发明的回射结构的一个实施方案的剖视图。
图3是焊接之后本发明的回射结构的第一实施方案的局部俯视图。
本发明的上述的和其它的目的、特征和优势通过下面关于附图中举例说明的本发明的优选实施方案的更具体的描述将变得明显，在不同的视图中相似的参考符号处处表示相同的部分。这些附图不必按比例绘制，而是把重点放在举例说明本发明的原则上。
具体实施方法
本发明的优选实施方案描述如下。
现在将参照附图更具体地描述本发明的方法和装置的特征和其它细节并在权利要求书指出这些特征和细节。相同的数字在不同的附图中代表相同的条目。人们将理解本发明的特定实施方案是作为本发明的例证而非作为限制展示的。这项发明的主要特征能在不脱离本发明的范围的情况下被用于各种不同的实施方案。
如图1所示，回射结构10有由透明的热塑性薄膜组成的底层薄膜12。底层薄膜12可能是利用聚氯乙烯、聚偏二氯乙烯、聚氨酯、多氟烃聚合物或其它热变形温度相对低的热塑性材料制成的。在一个实施方案中，这样的低热变形温度在大约18O(82℃)和200(93℃)之间的范围中。该热变形温度是聚合物熔融并开始流动的温度。在另一个实施方案中，该热塑性材料是乙烯-四氟乙烯共聚物。
底层12对于可见光可以是透明的和可以是清澈的或着色的。
底层12可以有范围在大约0.003英寸和0.02英寸(0.0076厘米和0.051厘米)之间的厚度。在一个实施方案中，就聚氯乙烯片材而言该厚度是大约10密耳(0.0254厘米)。选定的厚度取决于制造方法(例如，无线电高频焊接或超声波焊接)、选定的热塑性材料和预期的回射结构特性。适合用来封口的方法的例子能在通过引证将其教导并入的美国专利第6,039,909、6,143,224和6,231,797号中找到。
棱镜阵列14是在底层12上形成的，该棱镜阵列可以包括立体角回射棱镜元素16。棱镜阵列14有窗口面18和棱镜面20。窗口面18附着在底层12上。
棱镜阵列14是利用透明聚合物形成的。棱镜聚合物可以有比底层薄膜高的热变形温度。作为替代，棱镜聚合物和底层薄膜可以有相似的热变形温度。举例来说，在一个实施方案中，棱镜阵列14的聚合物热变形温度可能是大约350(177℃)。
成形之后，该聚合物在室温下实质上是硬的，这被定义为实质上不易弯曲的。在棱镜阵列中聚合物的这种刚性允许棱镜元素保持它们的光学特性。棱镜阵列聚合物也可能是不可伸长的，这被定义为实质上能够在不断裂的情况下被绷紧。
用于棱镜阵列14的聚合物选自各式各样的聚合物，包括氨基甲酸乙酯、丙烯酸酯、纤维素酯、烯不饱和腈的聚合物、聚丙烯酸酯(包括但不限于氨基甲酸乙酯丙烯酸酯、聚酯丙烯酸酯和环氧树脂丙烯酸酯、硬环氧树脂丙烯酸酯的反应产物)，等等。其它的聚合物包括聚碳酸酯、聚酯和聚烯烃、丙烯酸化硅烷、硬聚酯型氨酯丙烯酸酯。优选，聚合物能浇注在棱镜模子中并用紫外辐射引发单体或低聚物聚合。作为替代，可以使用热变形温度低的聚合物。这些聚合物包括聚氯乙烯、1，1-二氯乙烯和其它卤化乙烯。
棱镜阵列14的个别棱镜元素16可以呈立方体一角的形状而且有范围在大约0.003和0.02英寸(0.0076和0.051厘米)之间的尖顶高度。在一个实施方案中，该尖顶有大约0.006英寸(0.015厘米)的距离。优选，每个尖顶有在大约0.004和0.008英寸(0.01和0.02厘米)之间的距离。
棱镜阵列14在刚性棱镜元素16相交的谷底22的厚度足够薄，以便在施加最小的力的时候该棱镜阵列14能沿着谷底22破裂和分离。在一个实施方案中，棱镜阵列14的厚度在介于大约0.0028和0.009英寸(0.007和0.023厘米)之间的范围中。
底层薄膜12为棱镜阵列14提供基体，明确地说，它提供一个棱镜元素16(优选棱镜元素16的窗口面18)能附着在其上的平滑表面。棱镜阵列14能用透明的粘合剂层压到底层薄膜12上。作为替代，棱镜阵列14可以直接浇注到底层薄膜12上。
作为替代，底层薄膜12和棱镜阵列14可以用相同的材料制成。在加热时，底层和棱镜能一起熔融和流动。
背衬24放在棱镜阵列14的棱面20上。背衬24是作为在面对棱镜阵列14的一面有热塑性涂层23的织物层形成的。该织物可能是热变形温度或熔融温度比底层高的尼龙。在其它的实施方案中，织物背衬24包括编织聚酯或微粉化聚酯。为背衬选定的织物可以包括多种细丝纤度。举例来说，该细丝纤度可能介于大约70但尼耳和大约210但尼耳之间的范围中。适当的尼龙织物的例子可从DAF Product，Inc.of Wycoff，New Jersey购买。该织物可能有任何宽度，例如36或48英寸(91.44或121.94厘米)。其它适当的织物可从Amerbelle Textiles of Vernon，Connecticut购买。已经发现，与用塑料片材形成的相比，该织物为回射结构提供更大的柔性。
织物背衬24在一面上包括足够的热塑性涂层23，以允许织物背衬24、棱镜阵列14和底层薄膜12与涂层结合在一起。适当的热塑性涂层23是在与底层薄膜大约相似的温度下软化的涂层，借此允许该涂层和底层薄膜12一起流动和形成粘结。举例来说，热塑性涂层23是可高频焊接的。适当的热塑性涂层23的例子可以包括热塑性的聚氨酯和聚氯乙烯。热塑性聚氨酯涂层的例子是从DAF Products Inc.购买的产品7558210 DTPU 75。其它适当的热塑性聚氨酯可从Amerbelle of Windsor，Connecticut购买。这样的热塑性材料有范围可能在大约180(82℃)和200(93℃)之间的低熔融温度。
棱镜阵列14似乎对第一层(底层薄膜12)与织物24上的涂层23的焊接起阻挡层的作用。焊接和形成片材的有效方法是把棱镜移开，以允许底层薄膜12和背衬24中的热塑性材料形成粘结。棱镜的金字塔形状促成不稳定性而且如果底层12能被软化，棱镜能移开或翻滚出来。如果棱镜阵列14是用热变形温度低的材料制成的，棱镜阵列14可能很容易与底层12和热塑性涂层23融合在一起。
高频焊接是在加热和加压下通过分子摩擦引起的熔融使两个热塑性表面结合在一起。材料里面的分子经受由每秒数百万次改变极性的电场引起的内应力。当温度超过底层薄膜12的熔点(热变形温度)的时候，在压力下两个表面坍塌而且合并，因此形成接缝。图2是焊接后有焊缝25的回射结构的实施方案的剖视图。
焊接可以使用高频或电介质封口设备来完成。适当的焊接设备包括按商品名Thermatron、Kosmos、Kiefel和Callanan出售的设备。该设备根据大约27.12MHz的高频振荡发生器的原理操作。压机有上压盘和下压盘。模具可以位于上压盘或下压盘之上。在升起的或升高的位置，有棱镜阵列的底层薄膜12和背衬薄膜被放在阳模之间。位于上压盘或下压盘上的模具有封口图案。在压机合拢时，施加高频能量，使底层薄膜12中和背衬薄膜的热塑性涂层中的极性分子摇动并且被加热到它们的热变形和熔点温度。
对底层薄膜和织物加压的模具包含平台和边缘。棱镜元素移动并且允许底层薄膜和织物相遇并因此合并或结合在一起。这个焊接量是受时间、温度和高频功率水平控制的。举例来说，在以每秒六英尺(1.83厘米)的速率形成有聚丙烯酸酯棱镜的氯化聚合物片材和织物上的热塑性涂层的时候，压盘压力可能是大约413.7kPa(60psi)和压盘温度大约为90(32℃)。高频能量可能是大约30千瓦。压盘电流可能是大约3.5直流安培，和栅极电流可能是大约0.08直流安培。
在承受高频能量之前在大约两秒钟的预封合步骤中可以用热压盘施加压力，然后在大约3.3秒的封合步骤中把该片材和棱镜暴露在高频能量之下，然后在承受高频能量之后的冷却步骤中持续大约一秒。
在一个实施方案中，所使用的模具是黄铜。平台可能是宽度范围从0.013英寸(0.0325厘米)到0.030英寸(0.075厘米)的中央倾斜或平坦的金属条。模具也可能是用镁、蚀刻钢、铜或任何技术上已知的其它适当的模具材料制成的。对于镁模具，内部的封口宽度被称为9点线重(0.013英寸，0.033厘米)，这是它们的蚀刻宽度的指示。然而，线重能从大约0.1点变化到3.0点，即从大约0.001英寸到0.042英寸(0.0025厘米到0.107厘米)。
用来准备实施方案的其它模具有外部的可撕封口，该封口是大约0.001到0.042英寸(0.0025到0.107厘米)的陡峭边缘。这允许把成形的回射结构从构架上撕下来，或沿着回射结构的周边撕掉来自非织物聚氯乙烯基体的废物。当使用内部封口的时候，为了不撕掉内部的单元，在可撕封口的高度以下将平台向下加工大约0.014英寸(0.036厘米)。在黄铜模具的情况下，内部封口保持在可撕封口的表面以下大约0.008英寸(0.02厘米)的高度。
黄铜模具可以用整块黄铜机械加工而成或者用黄铜条构成。
模具上的内部封口能形成众多有多轨迹窗口图案周边的单元36，这些周边在加到底层(第一)薄膜12、棱镜阵列14和背衬薄膜24(有涂层的织物层)上的时候导致一部分棱镜阵列14错位或熔融，借此允许底层粘结到涂层上。单元36的周边可以由有窗口的多条轨迹形成的。
诸如带子之类的产品也能通过形成通常在两边封合的有大约0.25英寸(0.64厘米)宽度的边缘制作。这个封口是按特定的图案制作的。该封口图案可能是立体的、砖块型的(沿着边缘有几层宽)、正方形的、菱形的、三角形的，等等。在一个实施方案中，该图案是许多排偏置的长方形(砖块图)，其中所述的长方形是大约0.0625英寸乘0.125英寸(0.16厘米乘0.32厘米)。模具的平台可能是平直的，因此对每个长方形形成一致的压痕。作为替代，如图3所示，这些单元可能是与结实的周边38一起形成的。
该图案为封口产品提供强度，其中所述产品是背衬空气的回射产品。它还在每个单元36中提供小袋，以致如果一段产品由于撕裂、戳破或泄漏而失效，该回射结构的剩余部分仍然在装饰性和反射两个方面起作用。
能量也能由用来把各膜层结合在一起的超声波能源、红外线能源或感应加热供应。适当的超声波焊接设备包括按商标名Branson和Dukane出售的设备。在连续的卷材处理中，底层薄膜12、棱镜阵列14和背衬薄膜24一起进有内部封口和图案的旋转模具。然后，该带状物向第二站进发，在那里边缘用旋转的轮形刀具封合在一起。如果轮形刀具不旋转，则该材料既不封合也不能在同一站把内部封口和边缘放到该带状物上。超声波插入式封口机也已经用来封合先前用高频封合的产品的边缘，从而允许把圆锥体或环焊接在一起。举例来说，超声波频率在大约1到2千瓦的功率水平下可能是20kHz。该回射片材能以每分钟5到20英尺(1.5到6.1米)的速率形成。
应该小心地保证底层薄膜12、棱镜阵列14和背衬薄膜24的界面在上下压盘的中点，以便优化高频能源产生的热量。
正常的封口停留次数和电介质设定应该被用作开始处理优化的基线。夹紧压力与用于传统的高频焊接的那些相比较应该是相同的。高频焊接机在功率输出和压力方面因制造商不同而有所改变，甚至在同一型号的不同机器之间也有所改变。通常，当设定可能因机器不同而改变的时候，针对不同的模具和背衬评价每台机器的性能是谨慎的。
夹钳压力太高或压盘或模具或两者不平可能造成过度封合。过度封合能使焊缝周围的材料强度降低而且能引起使印刷变得困难的不平表面。穿过背衬的封合能造成前表面稍微不平顺。如果封口的深度不太大，如果所施加的压力太微不足道，将导致缺乏或全然没有焊缝。
为了焊接棱镜片材，压盘和模具应该尽可能水平。这在刀焊时尤其明显。下限位装置应该用来防止模具推进基体太多。
焊缝强度能用下列方法测试：把该材料切开并且分别拉两块基体。如果任一块薄膜在焊缝之前撕裂，则该焊缝对于大多数应用是适当的。一般地说，最可靠的测试是将该材料的样品切开和尝试把基体分开。如果封合设备被适当地校准，模具和压盘被调平，而且压盘温度和电介质设定被维持，为了查证焊缝性能，应该只需要周期性的测试。
同等物
虽然已经参照优选的实施方案具体地展示和描述了这项发明，但是熟悉这项技术的人将理解不脱离权利要求书囊括的本发明的范围可以在形式和细节方面完成各种不同的改变。

Claims (29)

1.一种回射片材，其中包括：
a)包括热塑性聚合物的底层；
b)放置在所述底层上的棱镜层；
c)织物层，在所述的织物层的一面上有热塑性涂层，其中所述的热塑性涂层面向所述棱镜层，而且其中所述底层、棱镜层、热塑性涂层和织物层的一部分附着在一起形成封口。
2.根据权利要求1的回射结构，其中所述热塑性涂层包括热塑性聚氨酯。
3.根据权利要求1的回射结构，其中所述热塑性涂层包括聚氯乙烯。
4.根据权利要求1回射结构，其中所述织物层包括选自尼龙和聚酯的织物。
5.根据权利要求1的回射结构，其中所述热塑性聚合物包括聚氯乙烯。
6.根据权利要求1的回射结构，其中所述棱镜层包括聚丙烯酸酯。
7.根据权利要求1的回射结构，其中所述棱镜层包括聚氯乙烯。
8.根据权利要求1的回射结构，其中所述棱镜层和所述底层是利用相同的材料制成的。
9.根据权利要求1的回射结构，其中所述织物上的所述热塑性涂层包括大约8密耳的厚度。
10.根据权利要求1的回射结构，其中所述热塑性涂层包括熔融温度范围在大约180和200之间的聚氨酯。
11.根据权利要求1的回射结构，其中所述热塑性聚合物包括熔融温度范围在大约180和200之间的聚合物。
12.根据权利要求1的回射结构，其中所述织物层包括纤度范围在70和210但尼耳之间的细丝。
13.根据权利要求1的回射结构，其中所述棱镜层包括立体角棱镜。
14.一种用来形成回射片材的方法，该方法包括：
a)提供底层，包括具有放置在所述膜层上的棱镜层的热塑性聚合物；
b)将有热塑性涂层的织物层放置在所述织物层的面上，其中所述热塑性涂层面对所述棱镜层；
c)在有足够的热量存在的情况下用模具对所述的底层和织物层加压使织物上的热塑性涂层和底层把底层的部分贴到所述织物层的热塑性涂层上，借此形成回射结构。
15.根据权利要求14的方法，其中所述热塑性涂层包括热塑性聚氨酯。
16.根据权利要求14的方法，其中所述热塑性涂层包括聚氯乙烯。
17.根据权利要求14的方法，其中所述织物层包括选自尼龙和聚酯的织物。
18.根据权利要求14的方法，其中所述热塑性聚合物包括聚氯乙烯。
19.根据权利要求14的方法，其中所述底层和热塑性涂层被加热到范围在大约180和200之间的温度。
20.根据权利要求14的方法，其中所述热量是由高频加热提供的。
21.根据权利要求14的方法，其中所述棱镜层包括聚丙烯酸酯。
22.根据权利要求14的方法，其中所述棱镜层包括聚氯乙烯。
23.根据权利要求14的方法，其中所述棱镜层和所述底层是由相同的材料制成的。
24.根据权利要求14的方法，其中所述织物上的所述热塑性涂层包括大约0.8密耳的厚度。
25.根据权利要求14的方法，其中所述热塑性涂层包括熔融温度范围在大约180和200之间的聚氨酯。
26.根据权利要求14的方法，其中所述热塑性聚合物包括熔融温度范围在大约180和200之间的聚合物。
27.根据权利要求14的方法，其中所述织物层包括纤度范围在70但尼耳和210但尼耳之间的细丝。
28.根据权利要求14的方法，其中所述棱镜层包括立体角棱镜。
29.一种用根据权利要求1的回射片材制成的标志。
CN200680003383.1A 2005-01-31 2006-01-30 背衬织物的成卷材料和衣服带子 Pending CN101111786A (zh)

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