CN102015241A - 成型泡沫制品及其制造方法 - Google Patents

成型泡沫制品及其制造方法 Download PDF

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CN102015241A
CN102015241A CN2009801139080A CN200980113908A CN102015241A CN 102015241 A CN102015241 A CN 102015241A CN 2009801139080 A CN2009801139080 A CN 2009801139080A CN 200980113908 A CN200980113908 A CN 200980113908A CN 102015241 A CN102015241 A CN 102015241A
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周广林
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Abstract

一种成型泡沫制品(100)包括膨胀的非热塑性泡沫材料的泡沫芯体(110)，其结合于非膨胀的或极微膨胀的非热塑性材料的表皮(120)。聚氨酯是合适的非热塑性材料。表皮(120)可以是压缩成型的未膨胀的聚氨酯，而泡沫芯体(110)是用水作为起泡剂形成的。

Description

成型泡沫制品及其制造方法
技术领域
本发明涉及成型泡沫制品(molded foamed articles)，更确切地说，涉及包括表皮和泡沫芯体的成型泡沫制品，如扶手、座椅、玩具、玩偶脸部、计算机周边设备和附件配件等。本发明还涉及聚氨酯泡沫制品的模制方法。
背景技术
包含被外表皮包围的泡沫芯体的制品是已知的。例如，扶手、带衬垫的座椅和玩具球包含被保护性外表皮包围的有弹性的泡沫芯体。传统上，包含外表皮的泡沫制品通过美国专利第US 3,664,976号描述的使用自结皮泡沫或整体表皮聚氨酯(PU)泡沫的自结皮法形成，或如WO2007/115396描述的首先通过喷涂形成聚氨酯外层，然后通过“水发泡”形成泡沫聚氨酯芯体。由于与聚氯乙烯对环境有害特性相比PU的更好的环境友好特性，预期以水作为起泡剂使用PU生产泡沫材料会变得更普及。
传统泡沫制品方法的缺点是已知的。例如，自结皮法需要无公害和略有危险性的起泡剂。另外，喷涂法并不节省材料并且更加昂贵，适合于通过该方法生产的制品形状是更有限的。而且，WO2007/115396的扶手包括只覆盖泡沫制品顶部的外表皮，注意到这样的外表皮容易剥落，因此不适合使用于持久耐用的家具。
因此，改良的制造泡沫制品的方法和/或改良的泡沫制品将会是有益的。
发明内容
根据本发明，提供了包括膨胀的非热塑性泡沫材料的泡沫芯体的成型泡沫制品，其中该泡沫芯体结合于未膨胀的非热塑性材料的表皮。聚氨酯是合适的非热塑性材料。
表皮可以为压缩成型的未膨胀的聚氨酯，而泡沫芯体是用水作为起泡剂进行发泡形成的。未膨胀的聚氨酯提高了表面光滑，其优选用于多种应用。
这样的泡沫制品是具有优势的，因为能够使用较少的环境破坏性化学材料来形成该制品，并且可更精确地控制表皮厚度。
表皮可包含第一表面部分，该第一表面部分处于若干侧面包裹部分的中间，该侧面包裹部分确定了泡沫芯体的侧面范围；其中每一侧面包裹部分从第一表面部分以连续和/或无接缝的形式横向延伸。
包含连续包裹部分的泡沫制品减少了通常在这样的制品上发现的纵向薄弱线的存在，这样的薄弱线通常处于张力之下并且常常是这样的制品的表面破裂的起因，这会缩短该制品的使用寿命。
表皮由未膨胀的非热塑性泡沫材料如聚氨酯压缩成型。
根据本发明的另外一个方面，提供了通过在包含上模、下模和模芯的模子上的模制成型来形成泡沫制品的方法，上模和下模共同确定了用于容纳模芯的模腔，模芯被设置成在上模和下模闭合之后并且当模腔充满表皮形成剂时形成表皮，该方法包含：
·将表皮形成剂递送到模腔中，
·将模芯插入模腔中，模芯被设置成在上模和下模闭合之后压缩形成表皮层，
·以无膨胀或极微的膨胀固化表皮形成剂从而形成表皮层，
·将发泡剂递送到由表皮层形成的腔中，和
·固化发泡剂以形成泡沫芯体。
诸如聚氨酯的非热塑性材料可以是用于本方法的合适的表皮形成剂。聚氨酯表皮形成剂的优选密度可以是在1的范围内，膨胀的非热塑性材料的泡沫芯体的密度远低于1。
附图说明
现在将通过实例和参考附图来解释本发明的优选实施方式，其中：
图1是部分切开的露出横截面的扶手的实施方式的顶部透视图，
图2是图1的制品的底部透视图，
图3是图示正被充满表皮形成剂的下模的横截面图，
图4显示了根据本发明的一个方面通过压缩成型来形成表皮层部分，
图5图示了在表皮层形成之后将芯体形成剂递送到图3的下模中，
图6图示了在图5的步骤之后用于形成完整的扶手的一套上模和下模。
图7是显示泡沫模子和模芯的透视图，
图8是另外一个角度的图7的透视图，
图9仍然是另外一个角度的图7的透视图，
图10是另外一端的图7的透视图，
图11是模芯的透视图，
图12是另外一个角度的模芯的透视图，
图13是图示组合使用上模和下模，用表皮形成剂填充到下模中以形成具有包裹部分的表皮层的横截面图，
图14显示了使用上模和下模通过压缩成型形成表皮层。
图15图示了在已形成表皮层和刚性插入件在适当位置之后将芯体形成剂填充到模子中，
图16图示了具有泡沫芯体和外表皮的扶手的模内成型。
具体实施方式
优选实施方式的详细描述
参照图1和2，作为本发明的泡沫制品的示例性实施方式的扶手100包含膨胀的聚氨酯的成型泡沫芯体110，其被夹入成型外表皮120和刚性插入件130之间。泡沫芯体被模制成扶手的形状，包含被相对的次要表面部分分隔开的相对的主要表面部分。每一个次要表面部分确定了扶手的侧端，并包括弧形弯曲部从而侧端形成为圆形并包含确定扶手侧端的部分。侧端为圆形是出于人体工程学和安全的考虑。
刚性插入件是由硬塑料如聚碳酸酯模制成型的，并包含多个纵向延伸的肋，其从其上表面向上突出。在形成泡沫芯体的过程中将肋嵌入下部主要表面中。刚性插入件的下表面是用于连接于座椅的框架，因此包含基于此目的的锚固装置。刚性插入件还可以由钢、合金或其它材料制成。
压缩成型的聚氨酯层的外表皮形成为保护表皮，其结合于泡沫芯体。结合的外层横向延伸穿过整个上部主要表面和泡沫芯体的侧端直到它最终结合于刚性插入件的侧边。更确切地说，外表皮是一片单独的压缩成型层，其连续地包裹泡沫芯体的外表面，从而泡沫芯体完全被外表皮和刚性插入件包围。侧端处的外表皮的连续性是指在侧面弯曲部上没有在表皮加长制品(如扶手)中发现的纵向延伸的接点(running joint)。弯曲部上的这样的接点是暴露的弱点，其处于持续的张力之下，并且易于发展为裂缝并导致外表皮的剥落，尤其是当该弯曲部受到持续的碰撞。
接下来开始介绍本发明的第一个实施方式的扶手的形成，通过参考一套示例性模子和图3-6说明了示例性的模制方法。该套示例性模子包含上模210和下模220，其用于在模子闭合和材料固化之后压缩形成泡沫聚氨酯的表皮。
参照图3，将一定量的准备用于表皮形成的液体聚氨酯引入到下模中，如图3所示。在将预定量的液体聚氨酯引入后，用于表皮形成的模芯240被放置到合适的位置，并且叠加在下模上，如图4所示。然后使聚氨酯液体在不膨胀的情况下固化以形成表皮层。因为模芯240和下模220的形状互补，在进行化学反应的同时(通常是在加热的情况下)通过压缩形成预定厚度的聚氨酯表皮。这样形成的表皮的厚度可小于1.5mm，甚至1mm或更小。类似地，通过上模和其模芯之间的配合在上模上形成表皮的其余部分。更确切地说，模芯的形状设计为具有模腔并且适合于与上模配合以形成表皮的其余部分。当上模和下模闭合时，则形成完整的表皮。
当上和下表皮部分仍然分别在上模和下模中时，将粘合剂施加于表皮部分的自由表面从而促进与要形成的泡沫芯体的结合。接下来，形成较低密度的成型泡沫芯体的聚氨酯发泡剂被引入到下模中，如图5所示。与表皮形成剂(其未膨胀或只是非常低程度的膨胀)相比该芯体形成发泡剂具有较高的膨胀率，并且通过使用水作为起泡剂来膨胀从而在固化之后形成开孔结构的芯体。接下来，在刚性插入件被放置到合适的位置之后，具有形状设计为容纳刚性插入件的模腔的上模被叠加在下模之上，粘合剂也被用于促进与上、下表皮的结合。在上模和下模被放置在一起并且闭合之后，如图6所示，加热来固化发泡剂从而形成泡沫芯体，则形成了包含泡沫聚氨酯芯体的扶手。图7-12更详细地显示了用于该示例性实施方式的包含上模、下模和模芯的一套模子。
参照图13-16，说明了本发明的第二个实施方式的扶手的形成，该扶手包含连续包裹扶手的侧面弯曲部的外表皮。用于图示说明该形成方法的模子除了还需要一个另外的模芯330之外与第一个实施方式的基本相同。详细来说，模子包含上模310、下模320和模芯330，其中上模和下模共同确定了用于容纳模芯的模腔。模芯是刚性的，被设置成在上模和下模闭合之后并且当模腔充满了表皮形成剂时，通过模制压缩形成表皮。
模芯用于在模制操作过程中贴合于上模的模腔，并且其形状设计为当这样贴合时并且在上模和下模闭合之后确定表皮形成空间。参照图13，模芯的形状设计为与下模的模腔配合从而确定第一表皮形成间隙(gap)，并且使其形状设计为与上模的模腔配合从而确定第二表皮形成间隙，第一和第二表皮形成间隙共同确定了当上模和下模闭合并且模芯在合适的位置时完整的表皮形成间隙。尤其是，模芯包含每一侧端的包裹部分，其被设置成保持在模子闭合之后与上模和上模的表皮形成间隙。
为了形成表皮，将表皮形成液体聚氨酯引入到下模的模腔中，然后闭合配套模芯的模子。该闭合导致液体填充模芯和下模之间的间隙，以及模芯和上模之间的间隙，从而在固化压缩的泡沫材料之后在侧端形成具有连续包裹部分的软表皮。与第一实施方式相似，用作表皮形成剂的聚氨酯是未膨胀的，从而可获得无孔洞结构或基本没有开放孔洞的光滑表面。
在如图14所示形成表皮之后，下一个步骤是形成泡沫芯体。在该步骤中，刚性插入件130首先附着于上模，并且闭合上模和下模。刚性插入件具有与上模上形成的孔对齐的孔，从而芯体形成发泡剂可经这些孔被递送到模腔，如图15的横截面图具体示出的。在插入件已附着于上模，以及上模和下模闭合之后，芯体形成发泡剂被递送到模腔中，然后被固化从而形成具有开放孔洞结构的有弹性的泡沫芯体。与第一个实施方式相似，水被用作优选的起泡剂(blowing agent)从而减轻有害的环境影响。在固化过程中，例如用粘合剂，将泡沫芯体牢固地结合于表皮和刚性插入件，尤其是通过纵向延伸的肋。
尽管示例性实施方式中的泡沫芯体和外表皮是由聚氨酯制成的，可以理解聚氨酯只是一个适合于制造泡沫制品的合适的非热塑性材料的实例，可使用其它的非热塑性材料而不丧失普遍性。

Claims (26)

1.一种成型泡沫制品，包括膨胀的非热塑性泡沫材料的泡沫芯体，其结合于未膨胀的或极微膨胀的非热塑性材料的表皮。
2.根据权利要求1所述的泡沫制品，其中所述表皮是压缩成型的未膨胀的或极微膨胀的聚氨酯，而所述泡沫芯体是用水作为起泡剂形成的。
3.根据权利要求1所述的泡沫制品，其中所述表皮包括包裹部分，所述包裹部分包含所述泡沫芯体，其中第一表面部分在若干侧面包裹部分的中间，所述侧面包裹部分确定所述泡沫芯体的侧面范围；其中每一侧面包裹部分从所述第一表面部分以连续和/或无接缝的形式横向延伸。
4.根据权利要求1至3的任一项所述的泡沫制品，其中所述第一表面部分是适合于提供平常使用中的缓冲的主要表面。
5.根据前述权利要求的任一项所述的泡沫制品，其中所述表皮形成所述泡沫制品的外层或最外层，所述包裹部分是圆形的。
6.根据前述权利要求的任一项所述的泡沫制品，其中每一包裹部分容纳所述泡沫芯体的侧端并且包括多个凹入部分，所述包裹部分的所述凹入部分共同设置成使所述表皮的侧端朝向彼此，每一凹入部分都是无接缝或连续的。
7.根据权利要求7所述的泡沫制品，其中每一凹入部分包含两个圆形的凹入弯曲部，所述凹入弯曲部共同确定了所述泡沫芯体的厚度量变曲线。
8.根据前述权利要求的任一项所述的泡沫制品，其中所述泡沫芯体和所述外皮还结合于刚性插入件，所述刚性插入件位于所述第一表面部分的相对侧。
9.根据权利要求8所述的泡沫制品，其中所述表皮和所述刚性插入件共同确定了所述泡沫芯体的体积。
10.根据权利要求8或9所述的泡沫制品，其中所述刚性插入件在所述包裹部分之间侧面延伸并且沿着所述制品的长度纵向延伸，所述表皮在其自由侧端纵向结合于所述刚性插入件。
11.根据权利要求8至10的任一项所述的泡沫制品，其中所述刚性插入件包含纵向延伸的肋，所述肋被植入到所述泡沫芯体中。
12.根据权利要求8至11的任一项所述的泡沫制品，其中所述刚性插入件由硬塑料或金属如钢形成。
13.根据权利要求8至12的任一项所述的泡沫制品，其中所述刚性插入件包括用于锚固在家具上的固定装置。
14.根据前述权利要求的任一项所述的泡沫制品，其中所述表皮层由聚氨酯(PU)或乳胶形成。
15.根据前述权利要求的任一项所述的泡沫制品，其中所述泡沫芯体具有开孔结构。
16.根据前述权利要求的任一项所述的泡沫制品，其中所述泡沫芯体由膨胀的聚氨酯(PU)形成。
17.根据前述权利要求的任一项所述的泡沫制品，其中所述泡沫芯体由较低密度的聚氨酯形成，所述表皮由较高密度的聚氨酯形成。
18.根据前述权利要求的任一项所述的泡沫制品，其中所述表皮层的厚度小于或等于2mm，优选小于或等于1.5mm。
19.根据前述权利要求的任一项所述的泡沫制品，其中所述制品是扶手，所述第一表面部分适用于扶手。
20.根据前述权利要求的任一项所述的泡沫制品，其中所述制品是减震缓冲制品，如计算机外围设备的减震配件，所述第一表面部分适用于冲击力吸收。
21.根据权利要求1-20的任一项所述的泡沫制品，其中所述泡沫制品是玩具，如泡沫塑料球或玩偶，包含儿童友好型接触表面。
22.一种通过在包含上模、下模和模芯的模子上模制成型形成泡沫制品的方法，所述上模和所述下模共同确定用于容纳所述模芯的模腔，所述模芯被设置成在闭合所述上模和下模之后并且当所述模腔充满表皮形成剂时形成表皮，所述方法包括：
·将表皮形成剂递送到所述模腔中，
·将所述模芯插入所述模腔，所述模芯被设置成在所述上模和下模闭合之后压缩形成表皮层，
·以无膨胀或极微的膨胀固化所述表皮形成剂从而形成表皮层，
·将发泡剂递送到所述表皮层形成的腔中；和
·固化所述发泡剂以形成泡沫芯体。
23.根据权利要求22所述的方法，其中所述模芯被设置成在所述上模和下模闭合之后使无接缝的侧面包裹部分围绕其侧端逐渐形成，所述方法包括在所述上模和下模闭合之后逐渐形成所述表皮层的无接缝侧面包裹部分。
24.根据权利要求22或23所述的方法，还包括将刚性插入件附着到所述泡沫芯体上，并且将所述刚性插入件结合于所述表皮的所述包裹部分的侧端。
25.根据权利要求22至24的任一项所述的方法，其中通过在所述上模和下模闭合之后所述模芯与所述上模和下模之间的空间确定所述表皮的所述包裹部分的侧端。
26.根据权利要求22至25的任一项所述的方法，其中水被用作起泡剂。
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