CN104271349B - 大尺寸聚苯乙烯面板 - Google Patents
大尺寸聚苯乙烯面板 Download PDFInfo
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Abstract
用于在家具和内部设计应用中使用的面板(10)，包含由聚苯乙烯或高抗冲聚苯乙烯形成的连续外部表皮(12)。所述表皮(12)完全包封蜂窝状塑性芯体(14)。所述芯体(14)由热活化发泡性塑性颗粒材料形成。所述面板最大面的面积大于1m2。表皮和填料材料都可以包含回收塑料。
Description
本发明涉及由聚苯乙烯(PS)或高抗冲聚苯乙烯(HIPS)形成的面板或板材，其具有固体的、连续的外部表皮和蜂窝状芯体结构。具体而言，本发明涉及大尺寸的面板，其具有的最大面超过1m2的面积，并且厚度超过11mm(并且优选超过14mm)。
目前的家具制造方法已经从实木转向使用例如MDF、刨花板和玻璃纤维等复合材料来代替实木，并且使用例如为三聚氰胺或饰面等涂层来产生所期望的表面修饰或颜色。
纤维板或定向刨花板为家具和内部设计中常用的。然而，它们并不耐潮，并且因此作为二次加工需要被涂覆或者层压以实现可接受的表面修饰。这可以包括加入饰面或三聚氰胺涂层。因此这种类型的板材会在其生产中(无论是在一次加工还是二次加工中)使用粘合剂，并且它们一旦被层压就非常难于回收。因此，这种类型板材的主要形式就会被限制于内部使用，因为其并不是耐候性的。
聚苯乙烯和高抗冲聚苯乙烯为已知材料，通常用于小型的薄壁产品，例如衣架和酸奶罐。该材料作为薄层而被挤出，随后可被热成型为所期望的形状。能够使用目前的挤出技术来制造高至约6mm厚度的固体聚苯乙烯片材。然而，这样的PS或HIPS固体片材为非常易碎的并且具有差的抗冲性能。无法使用目前的技术来挤出厚度超过11mm的大尺寸PS或HIPS板材。即便能够制造，由固体PS/HIPS制成的尺寸为2440×1220mm(典型的工业标准尺寸)、厚度例如为19mm(在许多的家具和内部设计应用中所期望的典型厚度)的板材将具有约55kg的重量，其为非常重的并且因此而不适用于家具和内部设计应用。
此外，PS/HIPS为主要污染物，因为目前少量可被回收，并且丢弃的PS/HIPS在数百年的时间里不会被生物降解，而且耐光分解。因为材料的降解会产生具有潜在危害性的可能会污染地下水和空气的液态和气态副产物，所以当今的垃圾掩埋地点被设计为使与空气和水的接触最小化。然而，空气和水对于降解来说是必须的，并且因此垃圾掩埋设计实际上排除了废弃物的降解。
由此，目前的纤维板产品是难于回收，需要粘合剂，二次加工，遭受着湿气，并且具有与其加工相关的某些健康危害。硬木为非常昂贵的，会对环境产生影响，并且在使用之前需要进行各种处理。厚度超过约11mm的固体塑料板材会变得非常重，可能还会产生弯曲，并且是昂贵的。目前市场上不存在仅由PS或HIPS形成的厚度超过11mm的板材。
本发明提供了用于在家具和内部设计应用中使用的面板，所述面板完全地包封蜂窝状塑性芯体的连续外部表皮，所述外部表皮由聚苯乙烯或高抗冲聚苯乙烯形成，所述蜂窝状塑性芯体由热活化发泡性塑性颗粒材料形成，其中所述面板的最大面的面积大于1m2。
优选地，所述面板的总厚度大于11mm。
优选地，所述外部表皮包含回收的PS或回收的HIPS。所述芯体还可以包含混合的废弃塑料。所述芯体还可以包括增强部件。
所述对表皮进行模制以提供表面纹理(surface texture)和/或包括(incorporate)高温印刷膜。
所述面板可以包括至少一种抗真菌剂，抗细菌剂和阻燃剂，从而适用于给定的应用。
面板表皮优选由直接施加至加热模具的表面的塑性颗粒材料形成。
本发明现在将通过参考附图仅以实施例的方式而详细地描述，其中：
图1为根据本发明面板的透视图；
图2为图1的面板沿着线2-2的横截面；
图3为形成有防滑表面的本发明第二实施方式的透视图；
图4为形成有表面图形的本发明第三实施方式的透视图；和
图5为图4的的面板沿着线5-5的截面图。
图1描述了根据本发明的面板10，由PS或HIPS形成，并且具有长度1、宽度w和厚度t。典型地，所述长度可以是2440mm并且宽度为1220mm，其为典型的工业标准尺寸。在本发明中，所述厚度为11mm以上，并且优选超过14mm。
面板10包含连续的、固体的外部表皮12，其延伸于整个表面，并且不具有开口、通风孔、注射腔等。如在图2中所示的，表皮12完全地包封蜂窝状芯体14，所述蜂窝状芯体在具有非常大的强度的同时具有更低的密度，并且因此与固体表皮12相比，对于给定的体积具有降低的重量。所述蜂窝状芯体由热活化发泡性塑性颗粒材料形成。
面板10可以使用例如在GB 2460838中描述的方法来制造。在这里，提供两个加热的、开放的阴模。将塑性颗粒材料置于两个模具中并内衬于每个模具熔融形成表皮。将同样呈颗粒形式的膨胀性填料材料添加至一个模具中，并且该两个模具联合在一起以形成密闭的模腔。在热的作用下，两个表皮结合在一起以产生单个连续的表皮，其完全地包封填料材料，所述填料材料膨胀以形成蜂窝状芯体，在连续表皮内部填充可提供的体积。
作为选择，面板10可以使用如在WO2011/114119中描述的模塑装置来制造。这篇文献使用单个加热的阴模和非补充性的加热盖，其可以联合在一起形成模腔。如上，当模具和盖分离的时候，可将塑性颗粒材料放置为与二者相接触，从而熔融并形成塑性表皮。热活化发泡性塑性颗粒填料材料被放置在阴模中，其通过盖而被密闭，从而产生完全包封填料的连续表皮。来自模具的热会活化填料从而膨胀并填充表皮。
由此，面板10优选由其中模具被保持在一个位置的静态模制方法来制造，而不是由例如为挤出或滚塑或需要令模具通过输送装置而被移至烘箱中等的方法来制造。
GB 2460838描述了聚乙烯(PE)的使用。这种在制造过程中的收缩允许最终制品从模具中轻易地移除。之前认为PS和HIPS是不适用于这种方法的，因为它们会经历程度相当小的收缩。然而，由于它们较小的收缩，PS/HIPS面板可被成型为具有精确的尺寸，例如用作混凝土框架来代替夹板。
表皮12可以由新的或回收的PS或HIPS形成，其以颗粒的形式而被引入至模具中。芯体14可以由新的塑料或者混合的塑料废弃物形成，其可以包括PS或HIPS，其同样以颗粒的形式而被引入至模具中。
连续的外部表皮12为防潮的、耐刮擦的和刚性的，并且由强固但是轻质的蜂窝状芯体14支撑。
根据所使用的模具面板10可以成型为所期望的形状和尺寸。因此，虽然描述的面板呈矩形，但是其它的形状也是可能的。面板10还可以通过常规方法而被切割、成型和制作以产生不同的最终产品。
在制造过程中可以将对PS/HIPS表皮12添加颜色来制造具有所期望的最终使用颜色的面板10。因此，涂覆或层压就不再需要。
在平滑的模具中，可以获得非常平滑的表皮12的外表面。然而，在面板10的外部上也可形成纹理化或者装饰化的表面。所使用的模具的壁可以纹理化以对表皮12赋予给定的纹理。例如，如在图3中所示的，网纹板图样的凸显的凸起和/或凹陷16可被直接模制在表皮12内以在面板10的至少一个面上提供防滑表面。
表面装饰还可以通过在形成面板10之前在一个或两个模具内设置高温印刷膜18来提供。例如，如在图4和5中所示的，木纹效应可以通过膜18而被提供在至少一个面上，所述膜18在模制过程中结合至表皮12。因此，不需要饰面或层压。
面板10的表皮12和芯体14还可以包括材料和试剂以针对特定的客户应用改善其性能。例如，可添加诸如阻燃剂、抗真菌剂或抗细菌剂等。
可以在制造过程中将诸如钢网等增强部件包埋在芯体14内，从而为面板10增加强度和刚度。
可以对面板10的表皮12的厚度进行调节以适用于该应用。薄表皮12将给出更轻的面板10，同时更厚的表皮12将增加重量、强度和刚度。
由此，根据本发明的面板提供了对于MDF、夹板、纤维板和硬纸板的环境友好替换形式。所述面板可以由废弃材料制造，并在其使用期限结束时被再次回收为相同类型的另一个面板。特别地，其可以由目前少有回收的PS和HIPS提供。所述面板相对于现有替换材料还具有改善的性能，因为其防水、耐刮擦、并且强固和轻质。可以在一次生产过程中引入不同的表面修饰，因此不需要二次加工。
Claims (9)
1.用于在家具和内部设计应用中使用的面板，所述面板包含完全地包封蜂窝状塑性芯体的连续外部表皮，所述外部表皮由聚苯乙烯或高抗冲聚苯乙烯形成，所述蜂窝状塑性芯体由热活化发泡性塑性颗粒材料形成，其中所述面板的最大面的面积大于1m2。
2.如权利要求1的面板，其中所述面板的总厚度大于11mm。
3.如权利要求1或2所述的面板，其中所述连续外部表皮由回收的聚苯乙烯或回收的高抗冲聚苯乙烯形成。
4.如权利要求1或2所述的面板，其中所述芯体包含混合的废弃塑料。
5.如权利要求1或2所述的面板，其中所述芯体包括增强部件。
6.如权利要求1或2所述的面板，其中对所述表皮进行模制以提供表面纹理。
7.如权利要求1或2所述的面板，其中所述表皮包括高温印刷膜。
8.如权利要求1或2所述的面板，所述面板包括抗真菌剂、抗细菌剂和阻燃剂中的至少一种。
9.如权利要求1或2所述的面板，其中所述表皮由直接施加至加热模具表面的塑性颗粒材料形成。
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB1201039.3A GB2498717B (en) | 2012-01-23 | 2012-01-23 | Large format polystyrene panel |
| GB1201039.3 | 2012-01-23 | ||
| PCT/GB2013/050134 WO2013110930A1 (en) | 2012-01-23 | 2013-01-22 | Large format polystyrene panel |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CN104271349A CN104271349A (zh) | 2015-01-07 |
| CN104271349B true CN104271349B (zh) | 2016-09-21 |
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| Application Number | Title | Priority Date | Filing Date |
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| CN201380006326.9A Active CN104271349B (zh) | 2012-01-23 | 2013-01-22 | 大尺寸聚苯乙烯面板 |
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| Country | Link |
|---|---|
| US (1) | US20160001529A1 (zh) |
| EP (1) | EP2807027B1 (zh) |
| JP (1) | JP2015511134A (zh) |
| CN (1) | CN104271349B (zh) |
| AU (1) | AU2013213422B2 (zh) |
| CA (1) | CA2861843C (zh) |
| GB (1) | GB2498717B (zh) |
| HK (1) | HK1185585A1 (zh) |
| PL (1) | PL2807027T3 (zh) |
| RU (1) | RU2618053C2 (zh) |
| WO (1) | WO2013110930A1 (zh) |
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| ITPS20140014A1 (it) | 2014-10-24 | 2016-04-24 | Angelo Candiracci | Procedimento produttivo di pannelli prefabbricati e fusti per l'industria del mobile da arredamento e prodotti con tale procedimento ottenuti |
| CH719093A1 (de) | 2021-10-27 | 2023-05-15 | Boxs Ag | Verfahren und Vorrichtung zur Herstellung einer geschäumten Polymercompositplatte aus Misch-Kunststoffabfall. |
| US12043808B2 (en) | 2021-12-28 | 2024-07-23 | Afton Chemical Corporation | Quaternary ammonium salt combinations for injector cleanliness |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| ZA718171B (en) * | 1971-01-12 | 1972-09-27 | Lavorazione Mat Plast | Synthetic resin laminate and its manufacturing process |
| GB1408592A (en) * | 1972-07-20 | 1975-10-01 | Monsanto Ltd | Foamed resin sheet |
| US4136220A (en) * | 1976-07-14 | 1979-01-23 | Union Carbide Corporation | Process for the molding of plastic structural web and the resulting articles |
| US5695870A (en) * | 1995-04-06 | 1997-12-09 | The Dow Chemical Company | Laminated foam insulation board of enhanced strength |
| JP2001027009A (ja) * | 1999-07-13 | 2001-01-30 | Sumitomo Chem Co Ltd | 熱可塑性樹脂パネル |
| JP2001062864A (ja) * | 1999-08-31 | 2001-03-13 | Noritz Corp | 断熱性を有する樹脂パネル及びその製造法 |
| JP2002144495A (ja) * | 2000-11-16 | 2002-05-21 | Idemitsu Unitech Co Ltd | 積層体、およびこれを用いた建築用資材、梱包用副資材、自動車用部材、パーティション |
| JP2002327530A (ja) * | 2001-03-02 | 2002-11-15 | Nkk Corp | プラスチック複合パネルおよびその製造方法 |
| US7445840B2 (en) * | 2003-12-29 | 2008-11-04 | Seiki Kogyo Co., Ltd. | Weather-resistant synthetic wood material |
| WO2005105433A1 (en) * | 2004-04-30 | 2005-11-10 | Armacel Pty Limited | A timber substitute |
| MX336122B (es) * | 2008-04-14 | 2016-01-08 | Polyworks Inc | Metodo de embutición para la fabricacion de articulos de absorción de impactos y vibraciones y los articulos formados del mismo. |
| GB2460838C (en) * | 2008-06-09 | 2013-11-06 | Nicholas Stillwell | Process for moulding plastic articles |
| GB2478796B (en) * | 2010-03-19 | 2014-01-08 | Upcycle Holdings Ltd | Process for forming a mould |
| RU105621U1 (ru) * | 2010-09-15 | 2011-06-20 | Общество С Ограниченной Ответственностью "Интер-Ремонт" | Ячеистый материал |
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2012
- 2012-01-23 GB GB1201039.3A patent/GB2498717B/en active Active
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2013
- 2013-01-22 CN CN201380006326.9A patent/CN104271349B/zh active Active
- 2013-01-22 EP EP13702093.9A patent/EP2807027B1/en active Active
- 2013-01-22 AU AU2013213422A patent/AU2013213422B2/en active Active
- 2013-01-22 RU RU2014134441A patent/RU2618053C2/ru active
- 2013-01-22 US US14/373,764 patent/US20160001529A1/en not_active Abandoned
- 2013-01-22 CA CA2861843A patent/CA2861843C/en active Active
- 2013-01-22 PL PL13702093.9T patent/PL2807027T3/pl unknown
- 2013-01-22 JP JP2014553798A patent/JP2015511134A/ja active Pending
- 2013-01-22 WO PCT/GB2013/050134 patent/WO2013110930A1/en active Application Filing
- 2013-11-21 HK HK13113017.7A patent/HK1185585A1/zh unknown
Also Published As
| Publication number | Publication date |
|---|---|
| PL2807027T3 (pl) | 2024-08-19 |
| GB2498717A (en) | 2013-07-31 |
| CN104271349A (zh) | 2015-01-07 |
| WO2013110930A1 (en) | 2013-08-01 |
| GB2498717B (en) | 2014-06-25 |
| AU2013213422A1 (en) | 2014-08-21 |
| JP2015511134A (ja) | 2015-04-16 |
| CA2861843C (en) | 2020-01-07 |
| US20160001529A1 (en) | 2016-01-07 |
| AU2013213422B2 (en) | 2016-05-12 |
| HK1185585A1 (zh) | 2014-02-21 |
| RU2014134441A (ru) | 2016-03-20 |
| RU2618053C2 (ru) | 2017-05-02 |
| EP2807027A1 (en) | 2014-12-03 |
| EP2807027B1 (en) | 2024-04-10 |
| CA2861843A1 (en) | 2013-08-01 |
| EP2807027C0 (en) | 2024-04-10 |
| GB201201039D0 (en) | 2012-03-07 |
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