CN102869497A - 具有接合的峰和槽的层压泡沫 - Google Patents

具有接合的峰和槽的层压泡沫 Download PDF

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CN102869497A
CN102869497A CN2011800217130A CN201180021713A CN102869497A CN 102869497 A CN102869497 A CN 102869497A CN 2011800217130 A CN2011800217130 A CN 2011800217130A CN 201180021713 A CN201180021713 A CN 201180021713A CN 102869497 A CN102869497 A CN 102869497A
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J·戈登-达菲
A·博格瓦特
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Dow Global Technologies LLC
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Abstract

一种层压泡沫制品，其包含具有接合的峰和槽表面轮廓的至少两个泡沫板，其中在所述轮廓的至少一部分上保留表皮，并且其中所述泡沫板通过所述泡沫的接合表面之间的粘合剂彼此层压，彼此层压的方式使得以使一个泡沫表面的峰在邻接泡沫表面的槽内接合定位，并且其中所述层压泡沫制品具有超过200毫米的厚度。

Description

具有接合的峰和槽的层压泡沫
交叉参考声明
本申请要求2010年4月28日提交的美国临时申请No.61/328,685的权益，所述申请的整个内容在此通过参考并入。
技术领域
本发明涉及层压聚合泡沫板制品，其包含两个或更多个层压在一起的聚合泡沫板以增加泡沫板厚度，以及制备这样的层压泡沫板制品的方法。
背景技术
在聚合泡沫板领域有制备厚度超过200毫米的板并且这样做时不使用氯氟烃发泡剂的需求。这种厚度的泡沫板适宜制备具有高水平热绝缘的建筑结构以及其他结构例如停车场结构。不幸的是，利用非氯氟烃发泡剂很难挤压出厚度超过200毫米的优质聚合泡沫。
自由堆叠较薄的板是达到更大厚度的一种方法，但是因为这样的板在装配期间可能滑移并且如果没有装牢的话甚至在就位时也可能滑移，所以它是不理想的。滑移是停车场应用的特别顾虑，泡沫板在这种应用中随着车辆在它们上面移动而可能经历频繁的剪切力。此外，在建筑工地将许多板堆叠在一起增加了操作和安装许多板的劳动难度，并且还产生水分在板之间蓄积并从而增加导热性的机会。
将多个板胶粘在一起，可获得理想厚度的单个层压板。然而，在应用中经常需要泡沫板具有水蒸汽渗透性，希望均匀的水蒸汽渗透性，以避免结构构架捕集水分。除非多个板以保持透过泡沫板的水蒸汽渗透性的方式胶合，否则胶合界面的水分积蓄可能是成问题的。欧洲专利(EP)1213118公开了将板层压在一起同时保持透过所述泡沫和胶界面的水蒸汽渗透性的解决方案。EP 1213118需要从彼此邻接的泡沫板的整个表面去除泡沫外皮，然后用扩散开放粘合剂(diffusion open adhesive)将它们粘附在一起。
提供与两个粘合面上包含外皮的层压泡沫板相比保持或增加水蒸汽渗透性(降低水蒸气扩散阻力)、但是不需要去除泡沫表面的全部外皮的层压泡沫板，是理想的，并将推进现有技术。如果所述泡沫板层压特别耐受高剪切强度，将是更加有利的，这样它们将很适合地板和停车场应用。
发明内容
针对提供具有相对于两个粘附表面上包含外皮的层压泡沫板保持或增加的水蒸汽渗透性(降低水蒸汽扩散阻力)、而在所述泡沫材料粘合在一起之前不需要清除它们的全部表皮的层压泡沫板的问题，本发明提供了解决方案。此外，本发明进一步提供了相应获得层压泡沫制品的高剪切强度的解决方案。
在第一方面，本发明是如下的层压泡沫制品，其包含具有接合的峰和槽表面轮廓的至少两个泡沫板，其中在所述轮廓的至少一部分上保留表皮，并且其中所述泡沫板用所述泡沫的接合表面之间的粘合剂以使一个泡沫表面的峰在邻接泡沫表面的槽内的接合定位而彼此层压，并且其中所述层压泡沫制品具有超过200毫米的厚度。
在第二方面，本发明是将泡沫板层压在一起的方法，其包含以下步骤：(a)在所述泡沫板的表面中限定接合的峰和槽表面轮廓；(b)向具有接合的峰和槽表面轮廓的至少一个表面施加粘合剂；和(c)通过将一个板表面的峰定位在另一个泡沫表面的槽中，使得所述粘合剂在泡沫表面之间并接触这两个表面，从而将泡沫板的接合的峰和槽表面轮廓粘贴在一起。
本发明的方法可用于制造本发明的制品。本发明的制品可用于绝缘建筑结构例如家居、商业和停车场。
附图说明
图1示出了具有接合的轮廓构造的两个聚合泡沫板。
图2示出了图1的两个聚合泡沫板处于接合的定位。
图3示出了两个聚合泡沫板以偏置接合定位层压在一起以在相对边缘上产生高低缝(ship-lap)轮廓。
图4示出了三个聚合泡沫板以偏置接合定位层压在一起以在相对边缘上产生接合的舌槽式轮廓。
图5示出了具有梯形的峰和槽的聚合泡沫板。
图6示出了三个聚合泡沫板以接合的配置形成具有沿着层压泡沫制品边缘的高低缝的层压泡沫制品。
具体实施方式
试验方法是指到本文献的优先权日为止最新近的试验方法，除非用试验方法编号标明了日期。引用试验方法包含提及试验协会和试验方法编号。试验方法组织由下列缩写之一指代：ASTM是指美国材料与试验协会(American Society for Testing and Materials)；EN是指欧洲标准(European Norm)；DIN是指德国工业协会(Deutsches Institute fürNormung)；和ISO是指国际标准组织(International Organization forStandards)。
泡沫制品具有三个互相垂直的尺寸：长度，宽度和厚度。长度尺寸位于沿着泡沫制品的最长尺寸并通常沿着挤出泡沫制品的挤出方向。厚度尺寸是量值最小的尺寸，但是在例如立方体中可以等于长度。宽度共同垂直于长度和厚度，并可以具有等于或小于长度并且等于或大于厚度的量值。
“和/或”是指“和，或者作为一种替换”。所有的范围包括端点，除非另外指明。
本发明利用和/或包含聚合泡沫板(泡沫板)。所述泡沫板没有限制，可以是任何聚合泡沫板。通常，泡沫板选自聚氨酯泡沫板、膨胀泡沫珠板和挤出泡沫板。虽然聚合泡沫板的组成没有限制，但所述泡沫板必需具有接合的峰和槽表面轮廓。“接合的峰和槽轮廓”是峰轮廓和槽轮廓，其装配在一起使得峰轮廓装配进槽中，并且其中所述槽基本是峰的阴像——亦即，所述槽是大小和形状与峰基本相同的空间，于是所述峰(和峰与槽之间的任何粘合剂)基本填满所述槽轮廓。技术人员了解，将泡沫块完美装配在一起是有挑战性的，因此在限定接合的峰和槽轮廓中使用“基本上”来允许峰轮廓不太完美地接合和/或填充所述槽轮廓。理想地，95％以上、优选98％以上、更加优选99％以上和最优选100％的槽空间被接合的峰和用来粘合包含峰的板与限定了所述槽的板的任何粘合剂填充。通常槽的深度(以及接合的峰轮廓的高度)为2毫米(mm)或更多、优选5mm或更多和15mm或更少、优选10mm或更少。
所述至少两个泡沫板以一个泡沫板表面的峰在相邻泡沫板表面的槽内的接合定位彼此层压。“接合的定位”是使一个轮廓的峰装配在另一个轮廓的槽内的位置。以接合的定位放置泡沫板使一个板以自身为中心并相对于配对中的另一个板自我校准。每个接合的泡沫板表面可以具有仅峰轮廓、仅槽轮廓、或者峰与槽轮廓的组合。
在一个特别理想的实施方式中，至少一些、优选所有的峰都具有梯形轮廓，最优选等腰梯形轮廓。梯形轮廓类似具有峰的顶部和底部作为平行边的梯形。通常，梯形轮廓将在邻近泡沫板底部具有较大的平行边。然而，所述轮廓可以类似于燕尾榫，其中较大的平行边是离邻近泡沫板底部最远的边。梯形峰的接合槽将同样具有梯形轮廓。图1和2示出了具有接合的梯形峰和槽轮廓的板。板20具有梯形槽22和梯形峰24。板30具有梯形槽32和梯形峰34。峰24与槽32接合，峰34与槽22接合，形成图2中示出的层压泡沫制品10。图2示出了接合定位中的板20和30。
非特征性的，例如EP1213118的层状结构，在相互胶粘附着的表面的至少一部分上留有表皮。通常，表皮保留在峰轮廓的顶部。EP1213118特别需要在将泡沫板粘附在一起形成层压板之前去除所有表皮。本发明不需要在泡沫板层压在一起之前从其去除所有表皮，然而本发明却仍然可以达到可比拟的水蒸汽扩散渗透性系数并可以甚至比它们的外皮完整而一起层压的结构(外皮对外皮的定位)更高。
所述至少两个相邻的泡沫板在所述泡沫的接合表面之间具有粘合剂。理想的是，所述粘合剂是“扩散开放(diffusion open)”粘合剂。“扩散开放”具有DIN 4108-3(2001)中的定义，为具有0.5米或更少的水蒸汽扩散等效空气厚度(water vapor Diffusion equivalent air thickness)(SD-值)。这是对本文中采取的“扩散开放”的定义。按照DIN 4108-3(2001)确定材料是否是扩散开放的。利用扩散开放粘合剂的优点是相对于类似的使用非扩散开放粘合剂而言，层压泡沫制品可获得较高的水蒸汽渗透性(较低的水蒸汽扩散阻力)。扩散开放粘合剂可以覆盖全部的相邻表面或者可以只覆盖少于全部相邻表面的部分相邻表面。在一种实施方式中，扩散开放粘合剂主要位于峰轮廓的泡沫表皮上，也就是说，包含峰轮廓的表面上的大部分粘合剂是在仍然具有表皮的表面部分上。适合的扩散开放粘合剂的例子包括单和双组份聚氨酯、热熔性粘合剂和反应性粘合剂。所述扩散开放粘合剂可以是可发泡的粘合剂，例如单或两组份聚氨酯泡沫粘合剂。
如果粘合剂不是扩散开放的，那么用粘合剂涂覆每个相邻泡沫板的不到全部表面是理想的，以便在所述泡沫板之间达到理想的水蒸汽渗透性。例如，施加粘合剂可以只限于包含表皮的泡沫板轮廓部分。
尽管在层压的泡沫板之间的界面上具有泡沫表皮，但本发明的层压泡沫制品意想不到地具有高水蒸汽渗透性(低水蒸汽扩散阻力)。本发明的层压泡沫制品透过所述泡沫厚度的水蒸汽扩散阻力系数(μ)理想地为135或更少，优选130或更少，其包括即使相邻泡沫板之间的界面上存在泡沫外皮时透过层压泡沫板界面的渗透性。按照EN 12086的方法测量水蒸汽扩散阻力系数。
本发明的层压泡沫板进一步表现出较用包含相互粘合的平板表面的层压板可达到的更高的泡沫板层之间的剪切强度。通过将峰插入相邻板上的槽中，所述两个板锁定在构型中，并且不能容易地相对彼此滑动。结果，用本发明的层压方法理想地增加了剪切强度。长度尺寸中的剪切强度通常超过250千帕斯卡(kPa)，并且可以是300kPa或更多，甚至350kPa或更多。所述泡沫的横向(宽度)尺寸的剪切强度通常超过175kPa并可以超过190kPa，甚至200kPa。因为所述泡沫板排除了彼此滑过，因此剪切强度通常由可能在剪切破坏时扯开的任何个体泡沫板层的剪切强度限制。剪切强度按照EN 12090的方法测定。
所述层压泡沫制品的厚度大于200毫米，并且可以具有250毫米或更大、300毫米以上或更大、400毫米以上或更大、甚至500毫米或更大的厚度。实际上对目前的层压泡沫制品可以达到的可能厚度没有技术限制。以同样的方式，对可以层压在一起形成本发明的层压泡沫制品的泡沫板数量没有技术限制。通常，所述层压制品包含两个或更多个层压的泡沫板，但是它可以包含三个或更多个层压的泡沫板、四个或更多个层压的泡沫板、五个或更多个层压的泡沫板。所有相邻的板理相地、尽管不是必需的，在层压结构中具有接合的峰和槽轮廓。理想地，当三个或更多个泡沫板构成本发明的制品时，泡沫板处于夹心构造，其中相邻泡沫板之间有一个或多个泡沫板(内部板)。内部泡沫板可以具有在两个相对的表面上的峰轮廓、在两个相对的表面上的槽轮廓、在一个表面上的槽轮廓和在相对表面上的峰轮廓、或者在两个相对的表面上具有峰和槽轮廓的组合。以接合的配置与所述内部板层压的泡沫板具有可以与所述内部板的表面轮廓接合的轮廓。
在理想的实施方式中，层压的泡沫制品在相对的边缘上具有接合的搭接部分。接合的搭接部分包括高低缝和舌槽式轮廓。通过将一个或多个泡沫板构件与层压制品中的其他泡沫板构件偏置，可以容易地在本发明的层压泡沫制品中加入接合的搭接部分。例如，一个板相对于另一个偏置，在两个边缘上使得每个板延伸经过另一个板，在相对的边缘上产生搭接接头。当三个板层压在一起时，将中央板与其它板偏置将产生相对的舌槽式轮廓。图3示出了层压泡沫制品100，其中泡沫板200和300处于接合的定位，但是彼此偏置以在相对的边缘上形成接合的高低缝轮廓400。图4示出了层压泡沫制品1000，其中泡沫板2000、3000和4000处于接合的定位，但是彼此偏置以在相对的边缘上分别形成接合的舌槽轮廓5000和5500。
通过首先提供至少两个在其中限定了接合的峰和槽表面轮廓的聚合泡沫板来制备本发明的层压泡沫制品。以可想到的任何方式来限定接合的峰和槽表面轮廓，包括下列非穷举的可能性列举：直接模制成泡沫板，切割掉泡沫，压缩泡沫(例如将轮廓冷成形到泡沫板中)。当限定峰轮廓时，在所述峰轮廓上留下至少一部分表皮——通常在所述峰的最顶端。
向至少一个具有接合的峰和槽表面轮廓的表面并任选对两个表面施加扩散开放粘合剂。所述粘合剂可以主要位于峰轮廓的外皮部分，可以覆盖一个表面的全部或者可以覆盖一个表面的任何部分。
通过将一个板表面的峰定位在另一个泡沫表面的槽中，使得所述粘合剂在泡沫表面之间并接触这两个表面，从而将两个泡沫板的接合的峰和槽表面轮廓以接合的定位粘贴在一起。
实施例
下列实施例起到例证说明本发明的实施方式的作用。
使用STYROFOAMTM FLOORMATETM 200-A牌挤出聚苯乙烯绝缘板作为聚合泡沫板，制备下列各比较例和实施例(STYROFOAM和FLOORMATE是The Dow Chemical Company的商标)。所述聚合泡沫板是80mm厚、600mm宽和1200mm长。使用MOR-AD
Figure BPA00001625166000071
660M牌单组份粘合剂作为扩散开放粘合剂(MOR-AD是Rohm and Haas Chemicals LLC的商标)。按照下面对各样品的描述，以每平方米大约120克的负载量施加所述粘合剂。将板粘附在一起之后，让其在压力下固化12小时以确保最佳粘着。
利用EN 12090的方法，检验由此产生的每个层压泡沫制品在挤出(长度)和横向(宽度)尺寸上的剪切强度和剪切模量。还按照EN 1607的方法检验由此产生的层压泡沫制品的拉伸强度拉伸模量。拉伸试验通过施加垂直于板的邻接表面、垂直于接合表面的界面的力来进行。最后，按照EN 12086的方法测量透过泡沫的厚度尺寸(垂直于层压界面)的水蒸汽扩散阻力系数(μ)。
下面描述层压泡沫制品的样品，并带有表格，表明了剪切模量、剪切强度、拉伸模量、抗张强度和水蒸汽扩散阻力系数(μ)的试验结果。
比较例(Comp Ex)A：带有外皮的平板
将三个聚合泡沫板粘合在一起产生层压泡沫制品比较例A(CompEx A)，其中两个粘附表面上都具有外皮。在将板粘附在一起之前在每对粘附表面的一个的全部表面上施加粘合剂。由此产生的层压板，比较例A，总厚度为240mm。
比较例B：具有刨平表面的平板
从粘附表面上刨去表皮之后，将三个聚合泡沫板粘合在一起，产生层压泡沫制品比较例B(Comp Ex B)。在将板粘附在一起之前在每对粘附表面的一个的全部表面上施加粘合剂。由此产生的层压板，比较例B，总厚度为220mm。
比较例C：具有一个刨平表面和一个外皮的平板
从一个粘附表面上刨去表皮之后，将刨平的表面与包含表皮的表面粘着，从而将三个聚合泡沫板粘合在一起，产生层压泡沫制品比较例C(Comp Ex C)。在将板粘附在一起之前在每对粘附表面的一个的全部表面上施加粘合剂。由此产生的层压板，比较例C，总厚度为220mm。
实施例(Ex)1：梯形轮廓的接合表面
将三个聚合泡沫板的表面打磨成图5中显示的具有六个接合的梯形峰和槽的类似板500、550和600，同时在每个峰的顶部(梯形峰的两个平行边的短边)留下表皮。所述梯形峰大致具有下列尺寸：峰高10mm，峰顶部宽度45mm，峰底部宽度55mm。接合的槽具有恰好的负尺寸。打磨所述板，使得梯形峰和槽延伸泡沫板的全长，但是如果所述峰和槽延伸了宽度而不是长度，也预期有类似的结果。如图6所示，将板550、550和600以接合的形态粘附在一起，使得在由此产生的层压泡沫制品1500的相对边缘上产生15毫米高低缝450。在所述板粘附在一起之前，仅向45毫米宽的峰轮廓施加粘合剂。由此产生的层压板，实施例1，总厚度为220mm。
这四个样品的特征测试结果在表1中：
表1
Figure BPA00001625166000091
该数据说明了实施例1的成型层压板的强度相对于其他层压板构造的意想不到的结果，同时达到了超越外皮对外皮层压板的提高的水蒸汽渗透性(降低水蒸汽扩散阻力)。

Claims (10)

1.一种层压泡沫制品，其包含具有接合的峰和槽表面轮廓的至少两个泡沫板，其中在所述轮廓的至少一部分上保留表皮，并且其中所述泡沫板用所述泡沫的接合表面之间的粘合剂彼此层压，所述彼此层压的方式使得一个泡沫表面的峰在邻接泡沫表面的槽内接合定位，并且其中所述层压泡沫制品具有超过200毫米的厚度。
2.权利要求1的层压泡沫制品，其中所述粘合剂是扩散开放粘合剂。
3.权利要求1的层压泡沫制品，其中所述粘合剂覆盖少于每个接合表面的全部的部分。
4.权利要求1的层压泡沫制品，其中所述粘合剂主要位于泡沫表皮上。
5.权利要求1的层压泡沫制品，其特征还在于水蒸汽扩散阻力系数小于135，长度尺寸上的剪切强度超过250千帕斯卡，和宽度尺寸上的剪切强度超过175千帕斯卡。
6.权利要求1的层压泡沫制品，其中所述接合的峰和槽具有梯形轮廓。
7.权利要求1的层压泡沫制品，其中所述泡沫板相对于彼此偏置，使得沿着所述层压泡沫制品的相对边缘产生相对的接合唇缘。
8.一种将泡沫板层压在一起的方法，其包括以下步骤：
a.在所述泡沫板的表面中限定接合的峰和槽表面轮廓；
b.向具有接合的峰和槽表面轮廓的至少一个表面施加粘合剂；和
c.通过将一个板表面的峰定位在另一个泡沫表面的槽中，使得所述粘合剂在泡沫表面之间并接触所述两个表面，从而将泡沫板的接合的峰和槽表面轮廓粘贴在一起。
9.权利要求8的方法，其中所述粘合剂是单组份或两组份可发泡的粘合剂。
10.权利要求8的方法，其中所述泡沫板相对于彼此偏置，使得沿着所述层压泡沫制品的相对边缘产生相对的接合唇缘。
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CA2797669A1 (en) 2011-11-03
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