CN101674932A - 包覆泡沫模制品的方法 - Google Patents
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Abstract
本发明涉及一种用塑料薄膜包覆泡沫模制品的方法,其特征在于a)将所述泡沫模制品放置并固定于一个盒中,其中所述塑料薄膜置于盒壁和泡沫模制品之间,b)抽出塑料薄膜与泡沫模制品之间的腔室中的空气,c)从而将所述塑料薄膜压制于所述泡沫模制品上,并在压制步骤过程中维持真空。本发明还涉及首次通过使用所述方法获得的泡沫模制品,以及所述泡沫模制品的用途。
Description
本发明涉及一种用塑料薄膜包覆泡沫模制品的方法,其包括
a)将所述泡沫模制品放置并固定于一个盒(capsule)中,其中所述塑料薄膜置于盒壁和泡沫模制品之间,
b)抽出塑料薄膜与泡沫模制品之间的腔室中的空气,和
c)从而将所述塑料薄膜压制于所述泡沫模制品上,并在该压制过程中维持真空。
本发明还涉及首次可通过该方法获得的包覆的泡沫模制品,并涉及所述泡沫模制品的用途。
现有技术迄今为止仅描述了用于泡沫模制品的后续表面处理的复杂的饱和或浸渍方法(见US 6,607,817和DE 100 11 388)。在这些方法中,将泡沫板浸没在疏水剂或疏油剂的溶液中达到饱和,在轧制机中加压除去过量的液体,最后将所述泡沫板干燥。
对于泡沫模制品而言,只能对其形状、颜色和表面进行极小改变或不能进行改变。泡沫模制品常常不令人满意的具体特征为其外观及其性能,如触感和耐候性。
因此本发明的一个目的为寻找一种可对泡沫模制品的表面进行后续改进的方法。
令人惊奇地,现已发现本文开篇所提及的方法非常适合对泡沫模制品进行后续表面改进。
一种对门进行包覆的类似方法之前已于WO 01/032400中公开。但WO 01/032400并未揭示泡沫模制品是否可通过所述方法进行包覆以及如何进行包覆。
WO 01/032400中所述的方法通过引用的方式明确地纳入本文。尤其是明确引用WO 01/032400中的以下方法特征和装置特征,这些特征可单独使用或优选结合使用:
●红外线加热,其在施加压力之前加热塑料薄膜,优选至120-180℃——由此来避免所述薄膜产生气泡、裂开或者所述薄膜在成角度区域的应力致白。
●泡沫模制品和薄膜之间(腔室A)以及薄膜和盒壁之间(腔室B)分隔的腔室——有利地同时或优选相继地对腔室A和B抽真空。真空度通常被调节为低于50mbar或优选低于30mbar。从而抑制薄膜的起皱或薄膜与泡沫模制品的过早接触。薄膜通过将腔室B中由真空恢复到大气压同时仍维持腔室A中的真空而压到泡沫模制品上。
●用薄膜同时包覆泡沫模制品的相对两侧——这可通过以下方式非常简单地实现:将泡沫模制品固定于由木材、金属或塑料构成的框中,并借助于框顶端的夹具而使其保持在包覆腔室的中央。在所述泡沫模制品的下面引入另一张薄膜,从而在所述薄膜和底部盒壁之间形成第三腔室C。然后如上所述对所有三个腔室抽真空,从而使所述泡沫模制品在加热薄膜后通过打开腔室A和C而被双侧包覆。
●用粘合剂涂敷塑料薄膜或优选地泡沫模制品,这使得薄膜能长期粘附于泡沫模制品上。
令人惊奇地,本发明方法适于对半硬质泡沫、特别是软质泡沫进行包覆,这些泡沫迄今都未见有用塑料薄膜进行包覆。用于本发明的泡沫为符合DIN 7726的泡沫。用于本发明的弹性泡沫为符合DIN7726的泡沫:其在通过基于DIN 53 777的方法而简单变形了其厚度的50%后,于10分钟后没有发生超过其最初厚度2%的残余变形。本文所涉及的泡沫可为软质弹性的或者半硬质弹性的。半硬质弹性泡沫为一种符合DIN 7726的弹性泡沫,其根据DIN 53421/DIN EN ISO604测得的在10%压缩率下的压缩应力大于15kPa且小于80kPa。软质弹性泡沫为一种符合DIN 7726的弹性泡沫,其根据DIN53421/DIN EN ISO 604测得的在10%压缩率下的压缩应力为15kPa。
为了避免包覆过程中泡沫模制品的变形,在整个过程中将所述模制品固着于一个辅助框中。如果意欲将所述框保留在包覆的泡沫模制品成品中,则在包覆过程之前将其用合适的粘合剂喷涂,所述粘合剂而后在包覆过程中通过薄膜的热量而起作用。如果意欲在包覆过程后除去所述框,则不施用粘合剂,并且优选将薄膜用刀片沿所述框切除。
所用粘合剂优选包括基于聚氨酯的水性体系。可使用单组分体系,也可使用双组分体系。
PU分散体可用作单组分粘合剂,在此可提及的一个实例为150.50。PU分散体(例如150.30)与异氰酸酯(例如195.40)的结合物可用作双组分粘合剂。然而,基于丙烯酸酯或基于环氧树脂的粘合剂也通常适用于此。
在下面带有基于苯乙烯-丁二烯-苯乙烯共聚物的增粘剂的双层薄膜同样适用。当使用粘合薄膜时,通常可不再使用其他任何粘合剂。
粘合剂可通过常规方法如涂铺、辊涂施用或喷涂进行施用,本文特别优选喷涂法。粘合剂施用后在室温下干燥20分钟对于所述体系而言足以。
适于生产本发明泡沫模制品的泡沫的实例有:聚氨酯类,例如来自Elastogran GmbH的或;聚苯乙烯泡沫,例如来自BASF SE的或;聚丙烯泡沫,例如来自BASF SE的;以及来自BASF SE的三聚氰胺甲醛树脂泡沫(简称为三聚氰胺树脂泡沫,商标名为)。特别优选三聚氰胺树脂泡沫。本文中的软质泡沫通常为开孔泡沫。泡沫模制品的尺寸通常为DIN A4至门大小。泡沫板的长度可为最高至6m并且其常规厚度为50-2000mm。
由三聚氰胺-甲醛缩聚物组成的开孔泡沫具有极好的隔音能力和杰出的隔热特性。这些泡沫塑料的另一特征为着火时的安全性,以及高耐热性。这一具有吸引力的性能特征由于低密度而得到加强。
因此,这些由三聚氰胺甲醛缩聚物组成的开孔泡沫(简称为三聚氰胺树脂泡沫)出于降低噪音和/或节约能源的目的而用于建筑业和运输业中。
用于运输业——例如汽车构造、轨道车辆和造船——的一个特殊后果为,三聚氰胺树脂与例如润滑油、冷凝水或雨水等形式的液体接触。在使用三聚氰胺树脂泡沫降低噪音的发动机试验台以及机械舱中液体污染也可能存在。
由于泡沫的开孔性质和内在材料即三聚氰胺树脂的吸收性能,泡沫可吸收大量液体。直接与水饱和物接触,三聚氰胺树脂泡沫即变得饱和,此处一个实例即为清洁海绵。吸水量以体积计大于90%(体积%)。这同样适用于与机油的接触,尽管此时所吸收的量由于粘度较高而稍小。例如,发现与SAE粘度级为10W的机油直接接触的吸油量为约80体积%。
用塑料薄膜包覆可几乎完全阻止泡沫模制品对液体的吸收。
此外,用塑料薄膜包覆可使泡沫模制品的耐候性和触感得到明显的改善。
特别适用的塑料薄膜为聚氯乙烯、苯乙烯共聚物、聚丙烯、聚偏1,1-二氟乙烯、热塑性聚氨酯(TPU)和聚甲基丙烯酸甲酯(PMMA)。已证实,苯乙烯共聚物例如SAN、AMSAN,尤其是ASA,由于其具有耐候性而特别适合室外使用。对于例如ASA共聚物的情形,所述薄膜可用0.5-30重量%的热塑性弹性体改性。可用的典型热塑性弹性体类型为:TPE-O(基于烯烃的热塑性弹性体,主要是PP/EPDM)、TPE-V(基于烯烃的交联的热塑性弹性体,主要是PP/EPDM)、TPE-U(基于氨基甲酸酯的热塑性弹性体)、TPE-E(热塑性共聚酯)、TPE-S(苯乙烯嵌段共聚物,例如SBS、SEBS、SEPS、SEEPS、MBS)以及TPE-A(热塑性共聚酰胺,例如PEBA)。这些薄膜不仅可以多种素色使用,而且可具有印制表面。此外还可在薄膜的挤出过程中通过多种压花辊对表面进行构建。
所用薄膜的厚度为50至750μm,优选100至500μm,特别优选200至350μm。它们可由相应的原料颗粒通过已知的生产薄膜的方法制得,在此优选用于挤塑薄膜(cast-film)生产的挤出方法。
为了改善粘合性能,可对薄膜的一侧或两侧进行电晕处理。
由于包覆的泡沫模制品具有良好的隔热和隔音性能以及消音性能,其可有利地用于建筑领域。
本发明的模制品尤其可用作顶篷包覆层以及墙壁包覆层。
所述泡沫模制品的低重量以及其表面的易改变还使得它们对于展台的构建、屏幕分区以及房间隔断物具有非常好的适用性,并且很容易生产轻质布景。
本发明的泡沫模制品的隔热性能及其吸引人的表面和其高柔韧性使得它们对于例如电缆管道、卷帘框(roller-shutter casing)和窗帘悬挂设施(curtain rail system)的层压结构具有优良的适用性。所述模制品可快速适应普遍的需求,例如通过切割、弯曲等,并具有能安装到各凹处的柔韧性。该过程是可逆的并且在很多情况下不需要另外的夹具。
开孔泡沫通常对于向例如座位、床垫或席子(mat)提供填充物具有优良的适用性。如上所述,一种合适的塑料薄膜可提供吸引人的外表,其中一个实例为合成革。
该填充物可用于提高道路交通的安全性,例如用在车辆上行人保护区域中。例如,车辆的前扰流板可装配所述泡沫模制品。
然而,另一种可能为体育馆墙壁以及车库、停车场和中心护栏的包覆。至少在车辆高度包覆墙壁可用来避免在例如停车时对车辆的损坏。
应用实施例
用ASA薄膜对三聚氰胺树脂泡沫板的单侧包覆
用于单侧包覆的基材为由组成的软质泡沫模制品,为一种来自BASF SE的可商购获得的三聚氰胺甲醛树脂泡沫。该模制品长29cm,宽21cm,厚5cm。第一步操作由施用粘合剂开始。所用粘合剂包含一种基于聚氨酯的双组分水性体系(由粘结剂和硬化剂组成),其在即将施用前通过混合这两种单独组分生成。为了获得均匀混合物,将混合物在室温下用带有精密玻璃密封套(precision glass gland)的搅拌器搅拌至少3分钟。然后将粘合剂以80g/m2的量借助于Walther Pilot喷枪喷涂于该模制品两表面之一。然后使该模制品在室温下干燥20分钟。接着将该模制品置于一个合适大小的木框(壁厚2cm)中,该框恰好包围该模制品的外边缘。然后将固着于该框中的模制品固定于包覆盒中,其中待施用的塑料薄膜已放置在盒壁和模制品之间。此处该模制品已喷涂粘合剂的表面面向该塑料薄膜。所用塑料薄膜包括由S(一种来自BASF SE的ASA共聚物)组成的厚250μm的白色薄膜。然后将该盒中的泡沫模制品和薄膜之间的腔室(腔室A)以及薄膜和盒壁之间的腔室(腔室B)这两个分隔的腔室同时抽真空。一旦达到25mbar的真空度,即借助于已被置于该薄膜上方盒壁处(盒B中)的IR源将该塑料薄膜加热到150℃的温度。一旦达到该温度,即停止加热并用空气使腔室B恢复至大气压,但同时维持腔室A中的真空。腔室B中的进气产生过压,从而使加热的塑料薄膜在压力下被施加至该模制品的已经喷涂粘合剂的那个表面上。这样结束了该包覆过程。在该过程中通过IR源加热还使该模制品表面处的粘合剂起作用,从而在该方法一结束即达到了粘合剂和塑料薄膜之间的极其良好的粘合。一旦包覆过程结束,即将该包覆的模制品自盒中移出并移除环绕外边缘的木框。使用锋利的刀片手工除去包覆表面边缘处突出的薄膜。
Claims (19)
1.一种用塑料薄膜包覆泡沫模制品的方法,其包括
a)将所述泡沫模制品放置并固定于一个盒中,其中所述塑料薄膜置于盒壁和泡沫模制品之间,
b)抽出塑料薄膜与泡沫模制品之间的腔室中的空气,和
c)从而将所述塑料薄膜压制于所述泡沫模制品上,并在该压制过程中维持30mbar以下的真空度。
2.权利要求1的方法,其中,在塑料薄膜和盒壁之间,存在第二腔室,开始时同样也将其抽真空至30mbar以下,并在步骤b)和/或c)期间,使其恢复到大气压以便将所述薄膜压制到所述泡沫模制品上。
3.权利要求1的方法,用于泡沫模制品的双侧包覆,其中将所述泡沫模制品置于两张塑料薄膜之间,并在步骤b)和/或c)中,将以这两张薄膜划界的腔室抽成真空并维持。
4.权利要求3的方法,其中,在两张塑料薄膜和相应的盒壁之间,存在另外两个腔室,在步骤b)和/或c)期间使其恢复至大气压以便将所述薄膜压制于所述泡沫模制品的相对侧上。
5.权利要求1至4中任一项的方法,其中,在步骤b)之前,将粘合剂涂敷于所述泡沫模制品和/或所述塑料薄膜。
6.权利要求1至5中任一项的方法,其中所述泡沫模制品由聚氨酯泡沫和/或三聚氰胺树脂泡沫组成。
7.权利要求6的方法,其中所述泡沫模制品在步骤a)中被置于一个框中以确保所述薄膜在步骤b)和c)中均匀施加至所述泡沫模制品上。
8.可由1、2或5至7中任一项的方法获得的单侧包覆的泡沫模制品。
9.可由3至7中任一项的方法获得的双侧包覆的泡沫模制品。
10.权利要求1至9中任一项的方法,其中所述薄膜为可容易地进行后处理的底层包覆薄膜。
11.权利要求8至10的包覆的泡沫模制品,其中所述薄膜由一种或多种选自聚氯乙烯、苯乙烯共聚物、聚丙烯、聚偏1,1-二氟乙烯、热塑性聚氨酯和聚甲基丙烯酸甲酯的塑料组成,并且其层厚度为100-500μm。
12.权利要求11的包覆的泡沫模制品,其中所述薄膜由纤维增强塑料组成。
13.权利要求11的包覆的泡沫模制品,其中所述薄膜由SAN、AMSAN或ASA组成。
14.权利要求8至13的泡沫模制品用于隔热或隔音或用于消音的用途。
15.权利要求8至13的泡沫模制品用于顶棚包覆和墙壁包覆的用途。
16.权利要求8至13的泡沫模制品用于屏幕分区的用途。
17.权利要求8至13的泡沫模制品用于例如电缆管道、卷帘框和窗帘悬挂设施的层压结构的用途。
18.权利要求8至13的泡沫模制品用于向例如座位、床垫、席子、体育馆墙壁、车库、停车场或中心护栏提供填充物的用途。
19.权利要求8至13的泡沫模制品用于车辆上行人保护区域中的用途。
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PCT/EP2008/055491 WO2008135552A1 (de) | 2007-05-08 | 2008-05-05 | Verfahren zum beschichten eines schaumstoffformteils |
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EP3640287A1 (de) * | 2018-10-16 | 2020-04-22 | Röhm GmbH | Polyetherblockamid-poly(meth)acrylat-schäume |
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US3234065A (en) * | 1961-01-09 | 1966-02-08 | Best Plastic Container Corp | Method of laminating plastic film to plastic foam and of drawing the same, and foam-film laminates |
US4025974A (en) * | 1972-01-10 | 1977-05-31 | Lea James M | Air mattress and method of making the same |
US4256797A (en) * | 1976-09-02 | 1981-03-17 | Inmont Corporation | Contoured resilient vehicle trim panel |
DE7637031U1 (zh) * | 1976-11-25 | 1977-03-10 | Fa. Willi Illbruck, 5090 Leverkusen | |
DE3507667A1 (de) * | 1985-03-05 | 1987-08-27 | Irbit Research & Consulting Ag | Vorrichtung zum ueberziehen von schaumstoffplatten |
DE3622906A1 (de) * | 1986-07-08 | 1988-01-28 | Helmut W Diedrichs | Schaumstoffkoerper und verfahren und vorrichtung zu seiner herstellung |
DE4115839C1 (zh) * | 1991-05-15 | 1992-05-27 | Guenter 7441 Kohlberg De Klauss | |
JPH101554A (ja) * | 1996-06-18 | 1998-01-06 | Nisshinbo Ind Inc | 撥油性に優れたメラミン系樹脂発泡体 |
DE19801651A1 (de) * | 1998-01-15 | 1999-07-22 | Bayerische Motoren Werke Ag | Verfahren zum Aufkaschieren einer Kunststoff-Folie auf die Rückseite eines danach zu hinterschäumenden Dekormaterials |
JP3398836B2 (ja) * | 1998-01-19 | 2003-04-21 | 勤 中山 | パネル製造装置 |
EP1235680B1 (en) * | 1999-11-02 | 2003-08-06 | Richard Warrington George | Method and apparatus for thermoforming of plastic sheets |
US6764570B2 (en) * | 2001-08-27 | 2004-07-20 | Chun-Hsien Lee | Method and apparatus for bonding a coating to a web of cloth or foam |
CN2530801Y (zh) * | 2001-10-15 | 2003-01-15 | 王宝瑞 | 塑料发泡复合材料 |
EP1405872A1 (fr) * | 2002-10-03 | 2004-04-07 | Atofina | Utilisation d'un film à base de PVDF, de PMMA ou leur mélange pour recouvrir des objets en matériau thermodur |
JP2004299146A (ja) * | 2003-03-31 | 2004-10-28 | Matsushita Electric Ind Co Ltd | 積層装置および積層方法 |
US20050025929A1 (en) * | 2003-07-28 | 2005-02-03 | Smith Lance D. | Sandwich panel with interior barrier |
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