CN102015257A - 粘合泡沫元件的方法及其产品 - Google Patents

粘合泡沫元件的方法及其产品 Download PDF

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CN102015257A
CN102015257A CN2009801020527A CN200980102052A CN102015257A CN 102015257 A CN102015257 A CN 102015257A CN 2009801020527 A CN2009801020527 A CN 2009801020527A CN 200980102052 A CN200980102052 A CN 200980102052A CN 102015257 A CN102015257 A CN 102015257A
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约翰·迪克斯
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Abstract

本发明描述了一种将具有第一末端部分的第一长条泡沫元件粘合到具有第二末端部分的第二长条泡沫的方法。该方法包含如下初始步骤：熔化第一末端部分的第一表面部分从而产生第一熔融部分。然后将第一末端部分对接到第二末端部分。此后，使第一熔融部分固化从而在第一末端部分和第二末端部分之间形成接缝粘接。因此，本发明涉及在两个长条泡沫元件末端部分将其粘合在一起。泡沫元件之间的粘接通过熔化两个泡沫胶块的末端部分之一或两者的至少部分表面来形成。当两胶块对接或用别的方法相互接触时，此方法在原位形成了作为粘合剂的熔融区域。

Description

粘合泡沫元件的方法及其产品
相关申请的交叉引用
本申请要求2008年1月8日提交的临时专利申请S.N.61/019,715在美国法典第35章第119条(e)款下的优先权，将其内容并入本文以供参考。
技术领域
在一方面，本发明涉及一种粘合泡沫元件的方法。另一方面，本发明涉及通过这种方法所形成的产品。
背景技术
在本技术领域中，异氰酸酯类泡沫例如聚氨酯泡沫是已知的。聚氨酯泡沫多少有些特别：发泡并且同时至少发生部分聚合过程。因此，例如在使用传统冷发泡技术的聚氨酯泡沫的生产中，典型的配方包含：
·多元醇(和/或其它包含活性氢的物质)；
·水；
·催化剂；
·交联剂；以及
·聚异氰酸酯。
已知，可使用所谓铺板(slab)(同样称为“自由起发(free rise)”)技术和模压技术来生产异氰酸酯类泡沫，其产品通常分别称为板状泡沫和模压泡沫。
板状聚氨酯泡沫通常用作汽车顶蓬、家具减震材料(furniture cushioning material)、纸尿布束腰以及其它消费品的组件。
在典型的聚氨酯泡沫生产设备中，经常通过下述过程生产出来：将可形成泡沫的组合物分配入具有顶部开口的沟槽(同样已知为通道)以及运输机底部，从而当开始发泡时将组合物移出混合头。通常使用低压混合，并且低压混合涉及到在通常低于500psi(通常200-350psi)的压力下将用于泡沫生产的组分计量后放入装配有搅拌器(或其他合适的搅拌手段)的混合头。这些组分在混合头中混合，并且可形成泡沫的组合物膨胀，从而产生聚氨酯泡沫。如同在本技术领域中已知的那样，低压混合通常用于生产板块状泡沫。已知通过改变一种以上计量组分的性质和/或数量来改变所得泡沫的性能。
商用板块状聚氨酯泡沫设备通常产生具有如下尺寸的泡沫“胶块(buns)”：例如4英尺(高度)×6英尺(宽度)×100英尺(长度)，也可能是其他尺寸。然后取决于所生产泡沫的具体应用(例如，汽车顶蓬)的说明，将各泡沫胶块切为许多长度较短(例如，5英尺)泡沫胶块。然后长度较短的泡沫胶块切为适当厚度的薄片(例如，用于汽车顶蓬的为1/8至1/2英寸)。对于汽车顶蓬，随后将各薄片覆盖、修边并固定在汽车中。本技术领域中还知道，使各薄片经受进一步工艺步骤例如热成型，从而可以赋予平薄片更接近所设定的汽车顶蓬形状的大致相像的外观。
因此，通常用于生产汽车顶蓬的板块状聚氨酯泡沫已知是一种具有至少一个非轮廓形状的表面(例如，泡沫是“自由起发”泡沫)的泡沫(例如弹性泡沫)。
例如在《弹性聚氨酯泡沫》(第二版，1997，Ron Herrington和Kathy Hock编辑)的第五章和和第九章中，给出了汽车顶蓬的补充信息。
在生产出上述泡沫块后，通常使用粘合剂(一般为化学粘合剂)粘合相邻泡沫胶块的末端部分，并且随后在用被称为成环机(looper)的装置中以弯曲形式来环化所粘合的排列的泡沫胶块。成环机用于切割泡沫薄片的目的，泡沫薄片被卷起或堆叠存放起来用于进一步处理。通常，将化学粘合剂喷在各泡沫胶块的末端部分并且需要等待时间，从而允许末端部分彼此相互粘合。
该方法的问题是：在泡沫胶块块切为相对较薄的薄片之后，在对应于粘合在一起的泡沫胶块末端部分之间的接缝处，在相对较薄的薄片中产生了相对较硬的模缝线。当包含这种硬模缝线的泡沫薄切片随后进行火焰粘合(flame laminated)(或用其他方法粘附)从而修整用于汽车顶蓬、家具或其它用途的覆盖材料时，通过装饰包覆材料能够感觉到硬模缝。这导致需要裁弃那些具有硬模缝线的切片。实际上，此变为火焰粘合方法中废料的单一最大来源，其中所述火焰粘合方法用于将薄片变为在指定应用中使用的最终产品。
此外，使用化学粘合剂的现有方法需要用于粘合的等待时间，从而保障泡沫胶块的两个末端部分粘在一起。这导致用于加工泡沫胶块的机械设备的效率显著降低。
更进一步来说，大部分商用可用粘合剂是溶剂型，并且其使用会导致溶剂释放到环境中。
因此，理想的是提供解决这些问题的方法。更具体地说，理想的是提供一种用于粘合泡沫元件(例如基本上不含有上述硬模缝线的板块状泡沫胶块)的方法。由于生产率降低以及与使用这种粘合系统相关的环境条件，如果在避免需要使用化学粘合系统(以及相似的粘合系统)的同时也能进行这方法，那么将额外有利。
发明内容
本发明的目标是避免或者减少至少一个上述在先技术的缺点。
本发明的另一目的在于提供一种用于粘合泡沫元件的新方法。
因此，一方面，本发明提供一种将具有第一末端部分的第一长条泡沫元件粘合到具有第二末端部分的第二长条泡沫的方法，该方法包含下述步骤：
(a)熔化第一末端部分的第一表面部分从而产生第一熔融部分；
(b)将第一末端部分对接到第二末端部分；
(c)使第一熔融部分固化从而在第一末端部分和第二末端部分之间形成接缝粘接(seambond)。
另一方面，本发明提供一种通过这种方法所生产的泡沫产品。
因此，在更广义上，本发明一方面涉及在两个长条泡沫元件末端部分将其粘合在一起。泡沫元件之间的粘接通过熔化两个泡沫胶块的末端部分之一或两者的至少一部分表面来形成。当两胶块的末端部分相互对接或用别的方法相互接触时，此方法在原位形成了作为粘合剂的熔融区域。
此方法的优势在于避免使用化学粘合系统以及与上述系统有关的问题。更重要的是，此技术的使用导致了相对较软的接缝粘接的供应可相比于如上所述使用化学粘合系统所形成的接缝粘接。因此，当包含两个以上粘合泡沫胶块的方法的产品被切为相对较薄泡沫薄片时，那些包含接缝粘接的泡沫薄片仍可用于具有合格质量的接缝粘接的最终应用，从而避免或减轻上述裁弃问题。
此方法的进一步优势在于在泡沫胶块末端部分熔融区域形成粘接的等待时间比使用化学粘合剂所需的等待时间显著减少。这导致了制造水平的产量增加以及效率提高。
该发明的特点还涉及一种通过此方法形成的产品。
此外，该发明涉及泡沫产品形成物的进一步加工从而生产出相对较薄的泡沫薄片，或进一步加工(例如，在加工汽车顶蓬的情况下)从而生产出最终产品。当最终产品包含根据本方法产生的接缝粘接时，其用于消费品中仍然质量合格，不需要如同当前情况下使用化学粘合剂及其相似体系时那样要裁弃产品。
具体实施方式
通常来说，本方法是一种将具有第一末端部分的第一长条泡沫元件粘接到具有第二末端部分的第二长条泡沫的方法。该方法包括熔化第一末端部分的第一表面部分从而产生第一熔融部分。然后第一末端部分和第二末端部分对接或以其它方式相互接触(例如，优选用压紧)足以让第一熔融部分基本上凝固的时间，从而形成第一末端部分和第二末端部分之间的接缝粘接。
优选第一熔融部分基本与第一末端部毗连。
在熔化步骤(例如上述步骤(a))中，优选使热源通过第一表面部分附近。优选热源为火焰，尽管可使用其它热源(例如红外热源)。加热步骤优选旨在完成第一泡沫元件末端部分表面(优选整个表面)的熔化，从而获得在该表面的基本连续的熔融区域。此熔化区域可相对较薄(例如，厚度低于5mm，优选厚度从约1mm至3mm)。
在特别优选的具体实施方式中，该方法包含在步骤(b)(对接步骤)之前别的步骤，该步骤是熔化第二末端部分的第二表面部分从而产生第二熔融部分。此附加的加热步骤优选旨在完成第二泡沫元件末端部分表面(优选整个表面)的熔化，从而获得在该表面的基本连续的熔融区域。同样，此熔化区域可相对较薄(例如，厚度低于5mm，优选厚度从约1mm至3mm)。在此特别优选的具体实施方式中，上述步骤(c)进一步包含引起第二熔融部分固化从而在第一末端部分和第二末端部分之间形成接缝粘接。在此优选具体实施方式中，优选步骤(b)包含将第一熔融部分对接到第二熔融部分。同样，在此具体实施方式中，优选第二熔融部分基本与第二末端部毗连。
在高度优选的具体实施方式中，此熔化步骤应用于两个末端部分的表面，从而在每一末端部分产生基本连续的熔融区域(如上所述优选相对较薄的区域)。这导致基本连续的接缝粘接的产生。
当该方法包含熔化每个末端部表面时，优选使热源通过第二泡沫元件的第二表面部分附近。与第一泡沫元件相同，虽然其他热源也可使用，但优选热源为火焰。
尽管本方法可适合第一泡沫元件和第二泡沫元件具有不同尺寸的情况，但优选第一泡沫元件和第二泡沫元件具有相同尺寸。
尽管本方法可适合第一泡沫元件和第二泡沫元件具有不同横截面尺寸的情况，但优选第一泡沫元件和第二泡沫元件具有基本相同的横截面尺寸。
该方法有利于用于粘合如上所述的板块状泡沫胶块形式的泡沫元件。
在一个具体实施方式中，虽然可能为其他尺寸，但第一泡沫元件和第二泡沫元件中的一个或两者具有如下尺寸：长度最大约150英尺、高度最大约8英尺、和宽度最大约8英尺。优选第一泡沫元件和第二泡沫元件中的一个或两者具有如下尺寸：长度在约5英尺至约120英尺、高度在约3英尺至约6英尺范围内和宽度在约3英尺至6英尺范围内。更优选第一泡沫元件和第二泡沫元件中的一个或两者具有如下尺寸：长度在约50英尺至120英尺范围内、高度在约3英尺至约6英尺范围内和宽度在约3英尺至6英尺范围内。
在本方法的一个具体实施方式中，第一末端部分包含基本垂直于第一泡沫元件纵轴的第一表面；并且第二末端部分包含基本垂直于第一泡沫元件纵轴--即，这涉及了一个位置，该位置长条泡沫元件末端部分有效地具有垂直于长条泡沫元件长度的横截面表面。
在本发明另一具体实施方式中，第一末端部分包含相对于第一泡沫元件纵轴有倾斜角的第一表面，该倾斜角定义为第一斜角(例如30°-75°)；并且第二末端部分包含相对于第一泡沫元件纵轴有倾斜角的第二表面，该倾斜角定义为第二斜角(例如30°-75°)。更优选第一斜角和第二斜角基本互补(两角相加共计180°)——例如，这涉及了一个位置，在该位置长条泡沫元件末端部分有效地具有相对于长条泡沫元件长度方向具有倒角的横截面表面。
优选第一泡沫元件和第二泡沫元件中的一个或两者包含异氰酸酯类泡沫。更优选第一泡沫元件和第二泡沫元件中的一个或两者包含聚氨酯泡沫。最优选第一泡沫元件和第二泡沫元件中的一个或两者包含聚氨酯板块状泡沫。
当然，本方法可适合于粘合两个以上泡沫元件。
如上所讨论，本发明还涉及：
·通过上述方法生产的粘合的泡沫产品；
·用于生产泡沫部件的方法，其包含下述步骤：切割粘合的泡沫产品(优选沿粘合泡沫产品的纵轴方向)从而生产出包含接缝粘接缝(seam bond seam)的相对较薄泡沫部件；
·通过此方法生产的相对较薄泡沫部件，该方法进一步包含下述可选步骤：(i)形成具备预定形状的相对较薄泡沫部件；以及(ii)将装饰罩(trim cover)固定到泡沫部件的至少一个主表面从而产生包覆泡沫部件(covered foam part)；以及
·根据此方法生产的包覆泡沫部件。
虽然本发明已描述了具体实施方式和实施例，但是并不意味着可将本说明书理解为限制性意义。因此，具体实施方式的各种修改、以及本发明的其他具体实施方式，对参考本说明书的本领域技术人员来说是显而易见的。所以，所附权利要求将会覆盖任何此类修改或具体实施方式。
此处所提及的所有公开案、专利和专利申请案都以引用方式全部并入本文，其引用程度就如同将各公开案、专利或专利申请详细且逐一地以全文引用的方式并入本文。

Claims (31)

1.一种用于将具有第一末端部分的第一长条泡沫元件粘接到具有第二末端部分的第二长条泡沫的方法，该方法包含下述步骤：
(a)熔化所述第一末端部分的第一表面部分从而产生第一熔融部分；
(b)将所述第一末端部分对接到所述第二末端部分；
(c)使所述第一熔融部分固化从而在所述第一末端部分和所述第二末端部分之间形成接缝粘接。
2.如权利要求1所述的方法，其特征在于，所述第一熔融部分基本上与所述第一末端部毗连。
3.如权利要求1和2中任意一项所述的方法，其特征在于，步骤(a)包括使热源通过所述第一表面部分附近。
4.如权利要求3所述的方法，其特征在于，所述热源包括火焰。
5.如权利要求1至4中任意一项所述的方法，其特征在于，在步骤(b)之前还包含下述进一步步骤：熔化所述第二末端部分的第二表面部分从而产生第二熔融部分，步骤(c)进一步包括使所述第二熔融部分固化从而在所述第一末端部分和所述第二末端部分之间形成粘接。
6.如权利要求5所述的方法，其特征在于，步骤(b)包括将所述第一熔融部分对接于所述第二熔融部分。
7.如权利要求5和6中任意一项所述的方法，其特征在于，所述第二熔融部分基本上与所述第二末端部分毗连。
8.如权利要求5至7中任意一项所述的方法，其特征在于，所述进一步步骤包括使热源通过所述第二表面部分附近。
9.如权利要求8所述的方法，其特征在于，所述热源包括火焰。
10.如权利要求1至9中任意一项所述的方法，其特征在于，所述第一泡沫元件和所述第二泡沫元件具有相同的尺寸。
11.如权利要求1至9中任意一项所述的方法，其特征在于，所述第一泡沫元件和所述第二泡沫元件具有不同的尺寸。
12.如权利要求1至11中任意一项所述的方法，其特征在于，所述第一末端部分和所述第二末端部分具有基本相同的横截面尺寸。
13.如权利要求1至11中任意一项所述的方法，其特征在于，所述第一末端部分和所述第二末端部分具有不同的横截面尺寸。
14.如权利要求1至11中任何一项所述的方法，其特征在于，所述第一泡沫元件尺寸如下：长度最大约150英尺、高度最大约8英尺、宽度最大约8英尺。
15.如权利要求1至11中任何一项所述的方法，其特征在于，所述第二泡沫元件尺寸如下：长度最大约150英尺、高度最大约8英尺、宽度最大约8英尺。
16.如权利要求1至11中任何一项所述的方法，其特征在于，所述第一泡沫元件具有如下尺寸：长度在约5英尺至约120英尺范围内、高度在约3英尺至约6英尺范围内、宽度在约3英尺至约6英尺范围内。
17.如权利要求1至11中任何一项所述的方法，其特征在于，所述第二泡沫元件具有如下尺寸：长度在约50英尺至约120英尺范围内、高度在约3英尺至约6英尺范围内、宽度在约3英尺至约6英尺范围内。
18.如权利要求1至11中任何一项所述的方法，其特征在于，所述第一泡沫元件具有如下尺寸：长度在约50英尺至约120英尺范围内、高度在约3英尺至约6英尺范围内、宽度在约3英尺至约6英尺范围内。
19.如权利要求1至11中任何一项所述的方法，其特征在于，所述第二泡沫元件具有如下尺寸：长度在约5英尺至约120英尺范围内、高度在约3英尺至约6英尺范围内、宽度在约3英尺至约6英尺范围内。
20.如权利要求1至19中任何一项所述的方法，其特征在于，所述第一末端部分包含基本上垂直于所述第一泡沫元件纵轴的第一表面，所述第二末端部分包含基本上垂直于所述第一泡沫元件纵轴的第二表面。
21.如权利要求1至19中任何一项所述的方法，其特征在于，所述第一末端部分包含相对于所述第一泡沫元件纵轴有倾斜角的第一表面，该倾斜角定义为第一斜角；所述第二末端部分包含相对于所述第一泡沫元件的纵轴有倾斜角的第二表面，该倾斜角定义为第二倾斜角。
22.如权利要求21所述的方法，其特征在于，所述第一倾斜角和所述第二倾斜角基本互补(相加共计180°)。
23.如权利要求1至22中任意一项所述的方法，其特征在于，所述第一泡沫元件和所述第二泡沫元件中的一个或两者包含异氰酸酯类泡沫。
24.如权利要求1至22中任意一项所述的方法，其特征在于，所述第一泡沫元件和所述第二泡沫元件中的一个或两者包含聚氨酯泡沫。
25.如权利要求1至22中任意一项所述的方法，其特征在于，所述第一泡沫元件和所述第二泡沫元件中的一个或两者包含聚氨酯板块状泡沫。
26.如权利要求1至22中任意一项所述的方法，其特征在于，还包括粘合两个以上泡沫元件。
27.一种通过如权利要求1至26中任意一项所述方法生产的泡沫产品。
28.一种用于生产泡沫部件的方法，包含下述步骤：切割如权利要求27所述的泡沫产品，从而生产出包含接缝粘接缝的相对较薄的泡沫部件。
29.一种根据如权利要求28所述方法生产的泡沫部件。
30.如权利要求28所述的方法，其特征在于，还包含如下步骤：
(a)形成具有预定形状的泡沫部件；以及
(b)将装饰罩固定于所述泡沫部件的至少一个主表面上，从而生产出包覆泡沫部件。
31.一种根据如权利要求30所述方法生产的包覆泡沫部件。
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CN103395199B (zh) * 2013-06-25 2016-07-20 延锋伟世通(北京)汽车饰件系统有限公司 装饰板用表皮的包边方法以及表皮结构

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Application publication date: 20110413