CN102548734B - 穿孔层压聚合泡沫制品 - Google Patents

穿孔层压聚合泡沫制品 Download PDF

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Publication number
CN102548734B
CN102548734B CN201080042787.8A CN201080042787A CN102548734B CN 102548734 B CN102548734 B CN 102548734B CN 201080042787 A CN201080042787 A CN 201080042787A CN 102548734 B CN102548734 B CN 102548734B
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CN
China
Prior art keywords
foam
thermoplastic polymer
abutment surface
adhesive
perforation
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Fee Related
Application number
CN201080042787.8A
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English (en)
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CN102548734A (zh
Inventor
A·博格瓦特
J·戈顿-达菲
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Dow Global Technologies LLC
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Dow Global Technologies LLC
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Expired - Fee Related legal-status Critical Current
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Classifications

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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/303—Particular design of joint configurations the joint involving an anchoring effect
    • B29C66/3032—Particular design of joint configurations the joint involving an anchoring effect making use of protrusions or cavities belonging to at least one of the parts to be joined
    • B29C66/30325—Particular design of joint configurations the joint involving an anchoring effect making use of protrusions or cavities belonging to at least one of the parts to be joined making use of cavities belonging to at least one of the parts to be joined
    • B29C66/30326—Particular design of joint configurations the joint involving an anchoring effect making use of protrusions or cavities belonging to at least one of the parts to be joined making use of cavities belonging to at least one of the parts to be joined in the form of porosity
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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Laminated Bodies (AREA)
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Abstract

聚合泡沫制品，其具有至少两个分层定向的热塑性聚合物泡沫，每一个热塑性聚合物泡沫含有：包含聚合物表皮的邻接表面；垂直于所述邻接表面的厚度尺寸；直径小于一毫米、穿透所述邻接表面至小于泡沫的厚度尺寸的深度的穿孔；其中一个热塑性聚合物泡沫的邻接表面与另一个热塑性聚合物泡沫的邻接表面通过粘合剂邻接并粘合，从而使热塑性聚合物泡沫彼此贴合。

Description

穿孔层压聚合泡沫制品
交叉引用声明
本申请要求2009年9月25日提交的美国临时申请No.61/245,680的权益，其全部内容以引用方式合并于此。
技术领域
本发明涉及层压聚合泡沫制品和用于制备所述层压聚合泡沫制品的方法。
背景技术
聚合泡沫制品用作绝热材料。聚合泡沫制品用作建筑和结构应用、器械应用以及其中绝热重要的几乎任何其他应用中的绝热材料。增加聚合泡沫制品厚度趋于降低通过制品的热传导率(即增加热阻率)，所有其他性质相同。然而，增加泡沫厚度不一定容易，尤其对于挤压聚合泡沫制品而言。
挤压泡沫过程通过在很大程度上控制所得挤压聚合泡沫的尺寸和形状的泡沫冲模来去除可发泡聚合物。由于泡沫模口(die opening)的截面积增加以能够制备横截面更大的泡沫制品，因此挤压过程变得更加难以控制。例如，由于压力变得更加难以维持恒定，泡沫表皮开始变得不规则。由于聚合泡沫的横截面尺寸(包括厚度)增加，因此难以制备高品质挤压聚合泡沫。
制备显著厚度的高品质挤压聚合泡沫的一种方案是以分层方式将多层较薄的挤压聚合泡沫层压在一起。例如，EP1734193A1描述了将多层挤压聚合泡沫堆叠并粘合在一起以形成厚的绝热板。美国专利申请序列号61/100830(‘830)也描述了用以获得厚的声衰减制品的层压在一起的聚合物泡沫。在层压前用直径为一毫米或更大的针使‘830中的泡沫始终是穿孔的，从而能增加通过泡沫的气流。令人遗憾地是，仅将挤压聚合泡沫有效地和审美地层压在一起可能是富有挑战性的。挤压聚合泡沫通常在其表面上具有不完全平坦的聚合物表皮。因此，将含有其表皮的挤压聚合泡沫粘合在一起时可能会产生问题，因为泡沫表面之间的接触可能是偶发的。此外，如果表面不完全是平的，邻接泡沫表面之间可能存在气隙。气隙可以汲取并保持水分，这对于绝热而言是不合需要的。
EP1213118B1公开了通过在将它们粘合在一起之前首先从邻接聚合泡沫中去除表皮来制备层压的绝热泡沫制品的改进。通过去除表皮，可使泡沫表面变得平坦，且泡沫间的蒸汽可以比表皮残留的情况下更自由地传递。然而，从泡沫表面去除表皮需要刮削步骤，且产生大量废料聚合物，其也必须被处理或以某种方式再循环。
需要寻找一种方法，来优化挤压聚合泡沫之间的粘合，而不需要去除邻接泡沫表面的表皮，尤其是在如果界面处的拉伸结合强度超过单一泡沫结构时。然而更需要的是粘合界面上的泡沫之间的蒸汽仍然可以传递。
发明简述
本发明提供优化挤压聚合泡沫之间的粘合，而不需要去除邻接表面的表皮，同时还增强泡沫和粘合分界面之间的蒸汽传递的问题的方法。令人惊讶地，本发明是以下发现的结果：用直径小于一毫米的穿孔工具来穿孔聚合泡沫的邻接表面不仅促进泡沫之间的蒸汽传递，而且比如果用较大直径的穿孔工具来穿孔邻接表面时在层压聚合泡沫之间形成更好的粘合。更意外的是以下发现：直径小于一毫米的穿孔不仅形成超过较大直径穿孔的拉伸强度，而且可以达到大于单一泡沫结构的拉伸强度。这是意外的，因为本领域技术人员会预期较大直径的穿孔来提供用于粘合剂渗入的较大空腔从而提高表面之间的机械结合。令人惊讶地，较大直径的穿孔在层压泡沫之间形成较弱的拉伸结合强度。
第一方面，本发明提供聚合泡沫制品，其含有至少两个分层定向的热塑性聚合物泡沫，每一个热塑性聚合物泡沫含有：(a)包含聚合物表皮的邻接表面；(b)垂直于所述邻接表面的厚度尺寸；(c)直径小于一毫米、穿透所述邻接表面至小于泡沫的厚度尺寸的深度的穿孔；其中一个热塑性聚合物泡沫的邻接表面与另一个热塑性聚合物泡沫的邻接表面通过粘合剂邻接并粘合，从而使热塑性聚合物泡沫彼此贴合。
第二方面，本发明提供用于制备第一方面的聚合泡沫制品的方法，所述方法包括：(a)提供至少两个热塑性聚合物泡沫，每一个具有含有聚合物表皮的邻接表面、垂直于所述邻接表面的厚度尺寸和直径小于一毫米、穿透所述邻接表面至小于泡沫的厚度尺寸的深度的穿孔；(b)将粘合剂施加到至少一个邻接表面；(c)以分层定向定位两个热塑性聚合物泡沫，这样使得一个热塑性聚合物泡沫的邻接表面与另一个热塑性聚合物泡沫的邻接表面通过两个热塑性聚合物泡沫之间的粘合剂邻接；和(d)用热塑性聚合物泡沫之间的粘合剂将热塑性聚合物泡沫粘合在一起。
本发明的方法可用于制备本发明的聚合泡沫制品。本发明的聚合泡沫制品例如用于绝热。
发明详述
当日期未与试验方法号一起指出时，试验方法是指到本文件的优先权日为止的最新的试验方法。试验方法的参考文献包括试验协会和试验方法号的参考文献。试验方法组织参考以下缩写：ASTM是指美国试验与材料协会(American society for Testing and Materials)；EN是指欧洲标准(European Norm)；DIN是指德国标准化协会(Deutches Institute furNormung)；以及ISO是指国际标准化组织(International Organization forStandards)。
泡沫和泡沫制品具有相互正交的长度、宽度和厚度尺寸。长度量值等于具有最大量值的尺寸，且对于挤压泡沫而言通常为泡沫的挤出方向。宽度量值等于或大于厚度且可以等于长度。
“主表面”对应于具有泡沫或泡沫制品的任何表面的最大平坦表面面积的表面。平坦表面面积是表面投影在平面上从而避免在表面面积量值中考虑表面结构(例如，表面中的凹陷、突起或波浪)。通常，长度和宽度定义了聚合泡沫制品的主表面。厚度通常将主表面和相对表面分隔，所述相对表面也可以是聚合泡沫制品的主表面。
聚合泡沫的“表皮”或“聚合物表皮”是聚合泡沫(尤其是挤压聚合泡沫)表面的连续的聚合膜。所述聚合物表皮通常是非多孔的，且通常位于挤压聚合泡沫上。表皮可通过例如刮削法去除。
“分层定向”对应于一个组件表面与另一个组件表面邻接的定向。例如，当一个泡沫表面与另一个泡沫表面邻接时，两个泡沫处于分层定向。理想地，处于分层定向的泡沫具有其彼此邻接的主表面。
“邻接表面”是一旦制备本发明制品时，正在或将要与另一个热塑性聚合物泡沫的表面(“邻接表面”)邻接的热塑性聚合物泡沫的表面。
“可发泡粘合剂”是一旦施加至底物上或底物之间时，膨胀成泡沫的粘合剂。当将底物粘合在一起时，可发泡粘合剂可仍然是泡沫或者不是泡沫，但希望其仍然是泡沫结构。
“扩散开放式(Diffusion open)”在DIN4108-3(2001)中定义为水蒸汽扩散等效空气层厚度(SD值)为0.5米或更小。这是此处采用的“扩散开放式”的定义。根据DIN4108-3(2001)确定一种材料是否为扩散开放式。
本发明的聚合泡沫制品包含至少两种分层定向的热塑性聚合物。热塑性聚合物泡沫可以是彼此相同或不同，只要它们各自具有以下性质：(a)包含聚合物表皮的表面(“邻接表面”)；(b)垂直于所述邻接表面的厚度尺寸；和(c)直径小于一毫米、穿透所述邻接表面至小于泡沫的厚度尺寸的深度的穿孔。理想地但并不一定地，所述热塑性聚合物泡沫具有相同成分。
适当的热塑性聚合物泡沫包括膨胀聚合物珠粒泡沫和挤压聚合物泡沫。膨胀聚合物珠粒泡沫在它们如何制备以及它们的最终结构方面与挤压聚合物泡沫不同。膨胀聚合物珠粒泡沫包含彼此粘合的多个泡沫珠粒来形成泡沫结构。各泡沫珠粒具有围绕一组泡沫小室并限定该泡沫珠粒的表皮。在膨胀聚合物珠粒泡沫中，珠粒表皮形成以所有方向延伸遍及泡沫的表皮网络，通常使膨胀聚合物珠粒泡沫的表面互相连接。挤压聚合物泡沫不含围绕一组小室且以所有方向延伸遍及泡沫的这种表皮网络。值得注意的是，珠表皮明显地比小室壁厚且和小室壁不同。理想地，本发明聚合泡沫制品的至少一个，优选所有的热塑性聚合物泡沫是挤压热塑性泡沫。膨胀珠粒泡沫的表皮网络可作为热短路(thermal short)通过泡沫，其增加通过泡沫的导热性，且可作为水分渗入泡沫的导管，因为沿着邻接珠粒表皮具有可容纳水分的开放孔隙(open void)。
热塑性聚合物泡沫包含限定大量小室的热塑性聚合物基质。热塑性聚合物基质具有热塑性聚合物的连续相。通常，热塑性聚合物基质中50重量％(wt％)或更多、优选75wt％或更多、更优选90wt％或更多的聚合物是热塑性聚合物。热塑性聚合物基质中100wt％的聚合物可以是热塑性聚合物。
用于热塑性聚合物基质的适当的热塑性聚合物包括任何热塑性聚合物或热塑性聚合物的组合，前提是聚合物组合足以与所有泡沫形成相容。特别理想的热塑性聚合物包括烯烃的均聚物和共聚物，例如聚乙烯和聚丙烯，以及芳族单体的均聚物和共聚物，例如烯基-芳族聚合物。苯乙烯聚合物是特别理想的烯基-芳族聚合物，且包括聚苯乙烯均聚物和苯乙烯共聚物。适当的苯乙烯共聚物的实例包括苯乙烯与以下一种或多种物质的共聚物：丙烯酸、甲基丙烯酸、乙基丙烯酸、马来酸、衣康酸、丙烯腈、马来酐、丙烯酸甲酯、丙烯酸乙酯、丙烯酸酸异丁酯、丙烯酸正丁酯、甲基丙烯酸甲酯、醋酸乙烯酯和丁二烯。至少部分地归因于其高的使用温度，苯乙烯丙烯腈共聚物(SAN)是一种特别理想的热塑性聚合物。
热塑性聚合物泡沫可包含任何一种添加剂或一种以上添加剂的组合，通常分散在热塑性聚合物基质中。适当的添加剂的实例包括：红外衰减剂(例如，炭黑、石墨、金属薄片、二氧化钛)；粘土，例如天然吸收性粘土(例如，高岭石和蒙脱土)和合成粘土；成核剂(例如，滑石和硅酸镁)；阻燃剂(例如，溴化阻燃剂，例如六溴环十二烷和溴化聚合物；含磷阻燃剂，例如磷酸三苯酯；和阻燃剂包装，其可以包括增效剂，例如，二枯基和聚枯基)；润滑剂(例如，硬脂酸钙和硬脂酸钡)；和除酸剂(例如，氧化镁和焦磷酸四钠)。添加剂通常以基于聚合物总重量最多10重量％的浓度存在。
各热塑性聚合物泡沫可具有相同或不同的密度。理想地，至少一个，优选所有本发明热塑性聚合物泡沫的密度为40千克/立方米(kg/m3)或更小，优选38kg/m3或更小，更优选36kg/m3或更小，以及最优选34kg/m3或更小。较低密度的泡沫更易于操作，且通常比较高密度泡沫便宜。通常，热塑性聚合泡沫的密度为18kg/m3或更小，以在机械学上是合理的。根据DIN ISO 845或EN1602确定泡沫密度。
各热塑性聚合物泡沫可以独立地为开放式小室或闭合式小室泡沫。理想地，热塑性聚合物泡沫的开放式小室含量为30％或更少，优选20％或更少，更优选10％或更少，更优选5％或更少，且可以为1％或甚至0％。根据DIN ISO 4590确定开放式小室的含量。
至少两个热塑性聚合物泡沫具有用粘合剂彼此邻接和彼此粘合的邻接表面。邻接表面包含聚合物表皮，其覆盖50％或更多，优选75％或更多，更优选90％或更多，更优选95％或更多的邻接表面的表面面积。通常，邻接表面是热塑性聚合物泡沫的主表面，或者是与热塑性聚合物泡沫的主表面相对的表面。这些热塑性聚合物泡沫的厚度尺寸垂直于其邻接表面。此外，邻接表面以渗透邻接表面并延伸至热塑性聚合物泡沫的小于泡沫的厚度尺寸的深度的方式穿孔。因此，穿孔通过邻接表面延伸入各邻接泡沫，但并非自始至终通过任一泡沫。
粘合邻接的热塑性聚合物泡沫的邻接表面的粘合剂可以是本发明最宽范围内的任何粘合剂。理想地，粘合剂是扩散开放式的，特别是如果粘合剂覆盖其粘合在一起的一个或两个泡沫的整个邻接表面。适当的扩散开放式粘合剂的实例包括单组分和双组分聚氨酯、热熔性粘合剂和反应性胶粘剂。
通常，将粘合剂施加到一个邻接表面，然后将两个热塑性聚合物泡沫的邻接表面粘合在一起。或者将粘合剂施加到两个邻接表面，然后将邻接表面粘合在一起。通常，粘合剂以40克/平方米(g/m2)、优选80g/m2或更高的浓度存在于邻接表面之间。同时，理想地，粘合剂以1500g/m2或更低、优选250g/m2或更低的浓度存在。浓度为相对于通过粘合剂粘合在一起的两个邻接表面中的一个表面的表面面积。
热塑性聚合物泡沫中的穿孔的直径为一毫米或更小。考虑到泡沫制品所达到的拉伸强度，这是本发明特别意外的方面。通常，预期在较大直径的穿孔中发生最佳粘合，这样使得粘合剂可以渗入穿孔从而提高泡沫的机械结合。形成本发明的研究发现这不是事实。事实上，一毫米或更小的穿孔具有相比较大的直径穿孔更大的粘合强度。通常，穿孔的直径是一毫米或更小以及0.1毫米或更大，优选0.5毫米或更大。穿孔的直径是穿孔的最大尺寸。理想地，穿孔的横截面形状为圆形，或接近圆形(直径长度比为2或更小)。
理想的穿过邻接表面的平均穿孔密度(mm2/cm2)是这样的：其在每平方厘米的邻接表面面积形成的穿孔表面面积(或穿孔面积)为一平方毫米或更大。理想地，穿孔表面面积为2.8mm2/cm2或更大，3mm2/cm2或更大，甚至5mm2/cm2或更大。穿孔表面面积是穿孔表面的平坦表面面积的50％或更少，从而在至少50％的表面上保留表皮。
本发明的制品需要至少两个分层定向的热塑性聚合物泡沫，但不限于仅两个分层定向的热塑性聚合物泡沫。换句话说，制品可以包含三个或更多个、四个或更多个、甚至五个或更多个的分层定向的热塑性聚合物泡沫。一种理想的实施方式包含各自具有厚度尺寸的至少三个热塑性聚合物泡沫，其中前两个热塑性共聚物泡沫具有至少一个邻接表面，且至少第三个热塑性聚合物泡沫具有两个相对的邻接表面，其中各邻接表面包含聚合物表皮和直径小于一毫米、穿透所述邻接表面至小于泡沫的厚度尺寸的深度的穿孔，其中两个热塑性聚合物泡沫的邻接表面与第三个热塑性聚合物泡沫的相对邻接表面邻接，且用粘合剂将热塑性聚合物泡沫彼此贴合。
本发明方法用于制备本发明制品。本发明方法包含至少四个步骤。
本发明方法的第一个步骤是提供至少两个热塑性聚合物泡沫，每一个具有含有聚合物表皮的邻接表面、垂直于所述邻接表面的厚度尺寸和直径小于一毫米、穿透所述邻接表面至小于泡沫的厚度尺寸的深度的穿孔。这些热塑性聚合物泡沫已在之前的本发明制品中描述并表征，包括穿孔特征。第一方法步骤可以包括穿孔泡沫以产生之前描述的穿孔热塑性聚合物泡沫。
本发明方法的第二个步骤是将粘合剂施加到至少一个邻接表面。粘合剂和涂层浓度已在之前的本发明制品中描述。粘合剂本身可作为一个泡沫施加。也就是说，粘合剂可以是可发泡粘合剂。粘合剂可以在最终制品中仍然为泡沫，或在处理期间皱缩，形成最终制品中的非泡沫粘合剂。
第三个步骤是以分层定向定位两个热塑性聚合物泡沫，这样使得一个热塑性聚合物泡沫的邻接表面与另一个热塑性聚合物泡沫的邻接表面通过两个热塑性聚合物泡沫之间的粘合剂邻接。
第四个步骤是用两个泡沫之间的粘合剂将热塑性聚合物泡沫粘合在一起。理想地，压制热塑性聚合物泡沫和它们之间的粘合剂，以确保粘合剂和泡沫之间的最佳接触。
所述方法还可以包括通过以下步骤提供并粘合本发明方法的至少三个热塑性聚合物泡沫：步骤(a)包括提供各自具有厚度尺寸的至少三个热塑性泡沫，其中前两个热塑性聚合物泡沫具有至少一个邻接表面，且至少第三个热塑性聚合物泡沫具有两个相对的邻接表面，其中各邻接表面包含聚合物表皮和直径小于一毫米、穿透所述邻接表面至小于泡沫的厚度尺寸的深度的穿孔，步骤(b)包括定位热塑性聚合物泡沫，这样使得两个热塑性聚合物泡沫的邻接表面与第三个热塑性聚合物泡沫的相对邻接表面邻接，和步骤(c)包括用泡沫之间的粘合剂将热塑性聚合物泡沫彼此粘合。
具体实施方式
本实施例用作阐明本发明的实施方式。为易于比较，样品及其性质概括在表1中。
参比：提供两块挤压的聚苯乙烯(XPS)泡沫板(ROOFMATESP-X，ROOFMATE是陶氏化学公司的商标)，各自厚度为60毫米。XPS泡沫板在其主表面上具有表皮。将两组分聚氨酯粘合剂(例如，比率为5∶1的SIKATM FORCE 7010和SIKATM FORCE 7710L100；SIKA是Sika AG公司的商标)以1000克/平方米表面的涂层密度施加到一块XPS泡沫板的主表面上。将另一块XPS泡沫定位在涂有粘合剂的一块泡沫表面上，并将它们安排在一起。将2.5千克/平方厘米的压缩力施加于板24小时，以将它们压在一起。根据EN1607所列标准测定板之间的拉伸粘合强度。
比较实施例A：如同参比制备并测试比较实施例(Comp Ex)A，除了用配备有直径为2毫米的针的滚筒在将要粘合在一起的XPS泡沫表面(邻接表面)上穿孔。滚筒上的针是这样设置的：使得XPS泡沫的穿孔表面的穿孔面积为1.64平方毫米/平方厘米表面面积(mm2/cm2)。穿孔进入XPS泡沫的深度是5毫米。
比较实施例B：如比较实施例A制备并测试比较实施例B，除了定位针，以使XPS泡沫的穿孔表面的穿孔面积为4.15mm2/cm2。
实施例1：如比较实施例A制备并测试实施例(Ex)1，除了使用直径为0.8毫米的针以及定位其以使XPS泡沫的穿孔表面的穿孔面积为0.50mm2/cm2。
实施例2-5：如实施例1制备并测试实施例2-5，除了定位针以使实施例2-5的XPS泡沫的穿孔表面的穿孔面积分别为1.57、2.78、2.80和5.12mm2/cm2。
表1
这些结果表明，与穿孔面积无关，用2毫米直径的针穿孔的泡沫制备的制品具有均匀的拉伸强度。此外，2毫米直径穿孔的拉伸强度小于用0.8mm直径的针穿孔、穿孔面积从低(例如，0.5mm2/cm2)到高(例如，5.1mm2/cm2)的泡沫制得的制品的拉伸强度。令人惊讶地，与穿孔面积无关，较小的穿孔比较大的穿孔产生更强的拉伸强度。
更意外地，当0.8毫米直径穿孔的穿孔面积是2.78或更高时，拉伸强度超过非穿孔泡沫的拉伸强度。然而，具有2毫米直径的穿孔的制品的拉伸强度始终低于非穿孔泡沫的拉伸强度。

Claims (11)

1.聚合泡沫制品，其含有至少两个分层定向的热塑性聚合物泡沫，每一个热塑性聚合物泡沫含有：
(a)包含聚合物表皮的邻接表面；
(b)垂直于所述邻接表面的厚度尺寸；
(c)直径小于一毫米、穿透所述邻接表面至小于泡沫的厚度尺寸的深度的穿孔；
其中一个热塑性聚合物泡沫的邻接表面与另一个热塑性聚合物泡沫的邻接表面通过粘合剂邻接并粘合，从而使热塑性聚合物泡沫彼此贴合。
2.如权利要求1所述的聚合泡沫制品，其中所述粘合剂选自单组分聚氨酯、双组分聚氨酯和热熔性粘合剂。
3.如权利要求1所述的聚合泡沫制品，其中粘合剂以每平方米邻接表面面积40到1500克的浓度存在。
4.如权利要求1所述的聚合泡沫制品，其特征还在于对于彼此邻接的两个邻接表面中的每一个表面，每平方厘米的邻接表面面积中，所述穿孔占据一平方毫米或更多。
5.如权利要求1所述的聚合泡沫制品，其特征还在于聚合物表皮覆盖各邻接表面的表面面积的至少50％，所述各邻接表面粘合至另一个邻接表面。
6.如权利要求1所述的聚合泡沫制品，包含各自具有厚度尺寸的至少三个热塑性聚合物泡沫，其中前两个热塑性聚合物泡沫具有至少一个邻接表面，且至少第三个热塑性聚合物泡沫具有两个相对的邻接表面，其中各邻接表面包含聚合物表皮和直径小于一毫米、穿透所述邻接表面至小于泡沫的厚度尺寸的深度的穿孔，其中两个热塑性聚合物泡沫的邻接表面与第三个热塑性聚合物泡沫的相对邻接表面邻接，且热塑性聚合物泡沫彼此贴合。
7.制备权利要求1所述的聚合泡沫制品的方法，所述方法包括：
(a)提供至少两个热塑性聚合物泡沫，每一个具有含有聚合物表皮的邻接表面、垂直于所述邻接表面的厚度尺寸和直径小于一毫米、穿透所述邻接表面至小于泡沫的厚度的深度的穿孔；
(b)将粘合剂施加到至少一个邻接表面；
(c)以分层定向定位两个热塑性聚合物泡沫，这样使得一个热塑性聚合物泡沫的邻接表面与另一个热塑性聚合物泡沫的邻接表面通过两个热塑性聚合物泡沫之间的粘合剂邻接；和
(d)用热塑性聚合物泡沫之间的粘合剂将热塑性聚合物泡沫粘合在一起。
8.如权利要求7所述的方法，其中所述粘合剂以泡沫施加。
9.如权利要求7所述的方法，其中所述粘合剂选自单组分聚氨酯、双组分聚氨酯和热熔性粘合剂。
10.如权利要求7所述的方法，其中步骤(a)包括穿孔所述至少两个热塑性聚合物泡沫的邻接表面，从而对于在步骤(b)中定位为彼此邻接的两个邻接表面，产生每平方厘米的邻接表面面积上一平方毫米或更大的穿孔密度。
11.如权利要求7所述的方法，其特征还在于步骤(a)包括提供各自具有厚度尺寸的至少三个热塑性泡沫，其中前两个热塑性聚合物泡沫具有至少一个邻接表面，且至少第三个热塑性聚合物泡沫具有两个相对的邻接表面，其中各邻接表面包含聚合物表皮和直径小于一毫米、穿透所述邻接表面至小于泡沫的厚度尺寸的深度的穿孔，步骤(b)包括定位热塑性聚合物泡沫，这样使得两个热塑性聚合物泡沫的邻接表面与第三个热塑性聚合物泡沫的相对邻接表面邻接，和步骤(c)包括用泡沫之间的粘合剂将热塑性聚合物泡沫彼此粘合。
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