CN104470711A - 用于制造层压板的方法 - Google Patents

用于制造层压板的方法 Download PDF

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Publication number
CN104470711A
CN104470711A CN201380032016.4A CN201380032016A CN104470711A CN 104470711 A CN104470711 A CN 104470711A CN 201380032016 A CN201380032016 A CN 201380032016A CN 104470711 A CN104470711 A CN 104470711A
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China
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phase
softer material
softer
hard material
laminate
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CN104470711B (zh
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雷·阿贝斯曼
恩希·法穆
温斯顿·麦凯尔维
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Gripmitt Co ltd
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Individual
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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Mechanical Engineering (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Physics & Mathematics (AREA)
  • Fluid Mechanics (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)
  • Laminated Bodies (AREA)
  • Shaping Of Tube Ends By Bending Or Straightening (AREA)

Abstract

本申请提供了用于制造硬的、重量轻的层压材料的方法。使具有凸起的尖状结构的纹理化后的薄片的至少一个板压合抵靠较软的平薄片，以将尖状结构嵌入较软的平薄片中。尖状结构从用刀元件上承载的一组齿状物在板材表面中雕刻的凹槽凸起。尖状结构可刺透较软的薄片，以使得突出的末端可被折转或钉牢以防止它们轻易撤回。两个这种纹理化后的薄片可用于将较软的薄片夹在中间并刺透较软的薄片，并且彼此共同钉牢。这样就生成了轻且硬的层压件。

Description

用于制造层压板的方法
技术领域
本发明涉及层压材料，更具体地涉及用于通过薄片或板层的层叠来层压以生产改进的结构材料的方法。
背景技术
对更轻、更硬、更便宜的结构材料的需求不断增长，结构材料优选具有所有这三个品质，以利用该结构材料制造更好的产品。
发明内容
层压件通过使至少一个较硬的薄片(层)与至少一个较软的薄片相结合来制造。在一个实施方式中，用两个外部较硬的薄片较软的芯部或中心薄片夹在中间。较硬的薄片优选由延性材料制成，诸如钢板。每个这种较硬的薄片都具有表面纹理化后的至少一个面，以使得大量尖状的、钉状的刺穿结构从该面凸起。优选地，纹理化后的薄片没有穿孔。芯部或中心薄片优选为较软的、可刺穿的材料，例如塑料板。一个或多个纹理化后的薄片压紧至少一个可刺穿的薄片，以使得可刺穿的薄片被刺穿并且优选地被穿透，从而刺穿结构的尖状末端相对彼此共同钉牢，从而将三个薄片锁定在一起。
根据本发明的第一方面，提供了用于制造层压板的方法。
第一相对硬质材料的薄板的至少一个面设置有表面纹理，该表面纹理具有多个凸起的且大致尖状的结构。然后使第一材料的纹理化后的面与第二较软材料的面相接触。将两个面压合在一起，以使得尖状结构中的至少一些进入第二材料以形成层压板。
可使用各种材料。在一个优选实施方式中，第一材料具有超过约80的布氏硬度，第二材料具有小于约30的布氏硬度。优选地，第一材料为金属(例如，钢)。优选地，第二材料为塑料、树脂、聚合物、泡沫、橡胶、木材或混合混合材料。
在一个实施方式中，第二材料是可固化材料，在这种情况下，“压合”步骤包括在部分固化的状态下应用第二材料，然后允许所述第二材料固化。
第一材料和第二材料可通过使层压板(或层压板的部分)在辊子之间经过而将第一材料和第二材料压合在一起。优选地，压合步骤至少使尖状结构的末端刺透第二材料，以使得末端在第二材料的第二面处突出。突出末端的可变形以使其指向第二材料的第二面之上或指向第二材料的第二面上或指向第二材料的第二面中(例如通过用辊子在末端上滚动，或者通过在末端上经由第一材料的第二薄板向下压制)。末端也可以(但无须)彼此相互作用(通过接触使彼此变形，或者在一些实施方式中彼此接合在一起)。
该方法可涉及在将第一材料和第二材料压合在一起之前加热第一材料和第二材料中之一或二者都加热。第一材料和第二材料可在加热状态下至少部分地组合在一起，然后冷却。在软化状态下将第二材料部分地组合至第一材料之前，可将第二材料加热至软化状态，然后，在进一步将材料压合在一起以形成层压板之前，可允许第二材料冷却并至少部分硬化。
该结构可具有钩状形状。该结构可以预弯曲成钩状形状。
根据本发明的第二方面，提供了用于制造层压板的连续方法。具有表面纹理的第一相对硬质材料的板由连续辊子提供，其中，表面纹理具有多个凸起的且大致尖状的结构。第一材料的纹理化后的面与第二较软材料的面相接触。然后将两个面压合在一起，以使得尖状结构中的至少一些进入第二材料以形成层压板。
优选连续地将第二材料进给至第一材料，并且在各个材料进给的下游将两个材料压合在一起。优选地，将第二材料连续地滚制在第一材料上。还可以在施加第二材料之前切割第一材料(或者可连续地例如从盒状件提供用于层压的预切割件)。可替代地，可在压合步骤之后将层压板切割成各种长度。
本申请还提供了通过上述方法过程中任一项形成的层压板。
根据本发明的第三方面，提供了层压板。具有表面纹理的第一相对硬质材料与第二较软材料相配合，其中，表面纹理具有多个凸起的且大致为尖状的结构，以使得，第一材料的尖状结构中的至少一些突出至第二材料中且大致为。
尖状结构中的至少一些可完全延伸通过第二材料。尖状结构的末端中的至少一些可在第二材料之上翻转或翻转至第二材料上或翻转至第二材料中，以便将第一材料和第二材料保持在一起。
根据本发明的第四方面，提供了多层层压板。至少一个双面板形成层压件的芯部。该双面板为第一相对硬质材料并且在其两个面上具有表面纹理。表面纹理具有多个凸起的且大致尖状的结构。第二较软材料的外层设置在双面板的两侧上，从而第二材料与第一材料相配合，以使得第一材料的尖状结构中的至少一些突出至第二材料中。
多层层压板还可包括分别设置在外层中的每个的外部的单面板的边界层。每个边界层都是单面的，边界层在其一个面上具有多个凸起的且大致为尖状的结构(其相对面是平的)。该面上的结构进行设置，以便延伸至其相应的外层的至少一部分中(应理解的是，还可使用该通用结构来提供更复杂的层压件：第一边界层、具有一个或多个双面纹理化后的板并且每个在两面上均由较软材料包围的芯部、第二边界层)。
在一个变型中，至少一个外层具有用于允许尖状结构进入的至少一个凹部。在另一变型中，一个外层具有用于允许尖状结构进入的至少一个相对较薄的区域。
附图说明
图1示出了由三个供给卷制造锁定层压板的连续方法，外部两个薄片具有刺穿结构并且中心薄片为较软的可刺穿材料。三个薄片在压力辊子之间被压合并锁定在一起，这还使刺穿结构靠着相对的外部薄片钉牢。图1示出了加热器和/或冷却器，加热器和/或冷却器可用于改变材料硬度，从而改变其刺穿性能。
图2示出了使用两套压力辊的实施方式(例如，当芯部薄片在标准温度下过硬而不能刺穿，或者过厚而不能刺透时)。第一轧辊开始层压，第二滚筒充分地将薄片压合在一起。
图3示出了具有刺穿结构的纹理化层状板的详图，该刺穿结构具有以尖状末端为端部的锥状横截面，从而占据表面。
图3a示出了使用钩状结构的变型的详图(例如，用于嵌入诸如水泥或树脂的流体芯部材料)。
图3b示出了刺穿结构可以如何折转以形成带倒刺的钩状件。
图4示出了相同的实施方式，其中，该结构已刺入相邻薄片并且尖端在相邻薄片的表面之上。
图5示出了具有已经刺透较软的芯部薄片的两个这种刺穿薄片，其中，尖端已经在该方法过程中钉牢薄片。
图6示出了两面都纹理化后的刺穿薄片的实施方式。
图7示出了五层层压件的另一实施方式，其中，两个外部薄片具有单个纹理化面，并且中心纹理化薄片的两面都被纹理化，其中，所有三个纹理化面均已刺穿相邻薄片并且其尖状末端已钉牢。
图8示出了钉牢的详图，其中，在可刺穿薄片的面上依次向下轧制末端至最终钉牢放置。
图9示出了大部分嵌入热软化芯部薄片的单个刺穿结构的详图，热软化芯部薄片也可能太厚而不能刺透。
图10示出了相同的实施方式，其中，芯部薄片已冷却恢复硬度，并且通过附加力完成的层压使结构的轻微附加进入，从而在刺穿结构附近创建压缩区域以将刺穿结构保持在压缩区域中。
图11示出了另一实施方式，其中，芯部材料为两个面都纹理化后的较硬的刺穿薄片，外部薄片可刺穿并且被压合至较硬的芯部上。
图12示出了过厚的薄片可如何通过在薄片中提供用于冲压的凹部使尖状结构钉牢。
图13示出了放大的短的纹理化材料部分。在右边，材料是直的，并且刺穿结构大致平行并与表面成直角。左边为材料的相同部分，该部分已经被弯曲以示出刺穿末端如何必然变得不平行或会聚，从而更靠近地移动在一起。然而，如果该结构已经刺穿至固体薄片(未示出)中，那么末端由此锁定在适当位置并且相对于彼此不能移动。这赋予了层压件高度的刚性。
具体实施方式
在以下描述中，“钉牢”(钉牢(clinching)、可钉牢的(clinchable)、钉牢的(clinched))这个词用于描述折转已经刺透两个或更多层并从该层延伸的针或钉子的暴露的末端的行为。钉牢在木建筑领域是习惯做法。钉牢类似于金属加工中的铆接，或者类似于紧固件的任何其他变形以防止其轻易撤回。钉牢的目的在与在这样接合的两个层压层之间赋予更大结合力。
术语“尖状结构(pointed structure)”或“多个尖状结构(pointedstructures)”在本文中作为通用术语使用，以描述任何类型的、在材料的表面上凸起的(用于嵌入或刺穿)钉状或针状结构(或者钩状的或带倒刺的结构)。“刺穿结构”是一个实施方式，其中，形成刺穿结构以在层压过程中刺透较软材料。方法过程中在本发明中，尖状(例如刺穿)结构已经从较硬层状材料的表面凸起。优选地，尖状(例如刺穿)结构可刺入相邻的较软薄片中，如果尖状(例如刺穿)结构比较软薄片的厚度更长，那么尖状(例如刺穿)结构可以突出。突出的尖端可进行折转或钉牢以生成本发明的‘锁定层压’实施方式。该刺透和钉牢为所产生的层压板带来非凡刚度的意想不到的益处。
图1示出了用于制造连续的锁定层压材料的方法。卷1供给较软的可刺穿材料的第一薄片1a，诸如聚乙烯，第一薄片1a将成为芯部薄片。卷2和2a供给较硬材料的外部第二薄片3b和外部第三薄片3c，外部第二薄片3b和外部第三薄片3c中每个都具有以刺穿结构20纹理化后的一个面3a。三个层状层在压力辊4、4a之间进给。在来自辊筒4、4a的压力下，两个外部薄片3b、3c的刺穿结构穿透芯部薄片1a，并通过相对的外部薄片钉牢，从而连续地将三个薄片锁定在一起，然后可将其割断成锁定层压的个体板6。可替代地，层压件5可作为批量产品收集在卷带盘(未示出)上(从而，该方法可为卷-卷方法)。该批量产品可为具体应用而进行进一步切割或成形，包括在施工现场按测量切割的应用。
辊筒4、4a可压靠材料“夹层件”的整个宽度或仅压靠限定区域(例如边缘)。
如果薄片1a对于刺穿结构20过硬而不能轻易刺穿和/或对于刺穿结构2过厚而不能完全延伸通过，可使用加热器10来软化该材料。然后，可在切割成层压板6之前使用冷却器11冷却层压带5。
在另一实施方式中，图2中所示的硬片状芯部薄片1b(诸如聚碳酸酯)可类似地在如上所述的外部纹理化后的薄片之间层压，但是其变化在于包括使用加热器10，以使得能够进行在通过第一轧辊4c、4d之后在每个薄片之间留出结构高度的例如5％的小接触间隙的部分刺穿。然后，冷却器11将薄片1a恢复至较硬状态，在这之后，第二轧辊4、4a完成刺穿并完全接触。这样，刺穿结构被强迫以短距离进入过硬或过厚的芯部薄片内，在过硬或过厚的芯部薄片围绕每个刺穿结构生成具有相当大的压缩张力的区域，从而产生意想不到的保持力。因为这些结构本身具有锥状横截面，所以实现次级锥度配合保持(在机械领域众所周知)，从而进一步增大保持力。这一切都导致适用于广泛用途的刚性优越的、成本低的层压件。该板可切割成较短的层压件6a。
图3中示出了较硬的外部薄片3b、3c的带纹理的面3a和平的面3，较硬的外部薄片3b、3c可以是相同或不同的材料，例如钢-钢或钢-铝。刺穿结构20具有刺穿的、尖状末端20a。在图4中，示出末端20a刺透薄片1a并在薄片1a上延伸。图3a示出该结构可具有钩状形状。例如，钩状件可在初始方法过程中固有地形成以准备带纹理的外部薄片(例如，使用同一申请人于2012年5月29日在加拿大提交的共同待审批的第TBA号加拿大专利申请“成批纹理化的材料片材(Bulk Textured MaterialSheeting)”中描述的方法；或者例如在第1,330,521号、第1,337,622号或者第2,127,339号加拿大专利中的任一项中所描述的方法，所有这些专利的公开均通过引用并入本文)。可替代地，更多直的竖立(例如，钉状)结构可预弯曲成更多钩状形状结构。这种预弯曲可使用平压板之间的压装置或轧辊来进行，以便将较薄的尖端弯曲成钩状件。钩状件形状提供了将纹理化表面3a接合或附接至可流动式芯部材料的方法，在接合或附接之后，可流动式芯部材料凝固，从而包围钩状件。例如，该设置可用于将带纹理的面3a固定至应用的、未固化或非固体材料，诸如水泥、树脂、熔化的聚合物、粘合剂等。这样做时，因为钉牢不需要刺透芯部，所以可使用较厚的芯部材料1a。
图3b示出了可以如何进一步形成或折转结构末端20a以形成向后弯曲的钩状件或倒刺20b。这种倒刺可有利地用于接合织物、软薄片，并且被压合至加热的薄片中。众所周知，倒刺形状用于抵抗去除，为本层压发明增加另一锁定动作。
在图5中示出两个较硬的外部薄片的结构正好刺透芯部薄片1a，以使得其末端已经通过压力抵靠相对的外部薄片的压力钉牢，从而创建本发明的锁定层压。图6示出了较硬的薄片3，较硬的薄片3的两面都以刺穿结构进行纹理化，以使得较硬的薄片3将成为两个较软的外部薄片之间的芯部(例如，如图7中所示)。在图7中，相同的双纹理化薄片被示出为芯部薄片，在任一侧上具有较软的可刺穿薄片并且在外部上具有外部较硬的纹理化薄片，从而创建全部能够钉牢在一起的五层层压件。
为了使末端20a的前进的清楚起见，图8仅示出了两个薄片，其中，末端20a在通过轧辊的同时通过抵靠第三表面(诸如铁砧)被压在一起以钉牢至完全钉牢的末端20b。图8还示出了可如何弯转20c末端以便使末端再次指向薄片内的示例以及压扁20d尖端的示例，其中，压扁的效果近似于铆接。
图9和图10示出了薄片3a上的一个刺穿结构20的详图，其中，刺穿结构20几乎完全接合至预软化的薄片1c中，并在薄片3a与薄片1c之间留出小接触间隙30。在第二压制之后，后硬化的薄片1d(薄片1c冷却至正常硬度)被刺穿附加的距离以闭合接触间隙并在整个结构周围创建‘压缩张力包封’40。当然，这适用于这种层压过程中的方法过程中所有结构。
图11示出了应用于具有较软的外部薄片1a的双纹理化的较硬的薄片3a的芯部的滚压层压方法，该外部薄片可具有相同或不同的材料和厚度。
图12中示出了当过厚的层压件阻止尖端突出时的两个不同的钉牢方法。凸缘1a’提供较薄的边缘部分，刺穿结构可通过该较薄的边缘部分出现以被钉牢。较厚的薄片1e中的凹部或腔41也可以向末端提供相同的通路以进行钉牢。钉牢工具(例如，小的辊子或压盘)可向下压入凹部41中或者压在较薄的边缘处以局部地钉牢暴露的刺穿结构。这样，层压件的具体区域可被钉牢而其他区域则没有被钉牢。
图13中示出了较硬的薄片3一部分，该部分具有放大的刺穿结构，刺穿结构与薄片的面成直角，并大致平行设置的。当该部分被弯曲时，结构末端必然保持与纹理化薄片成它们原有的直角并且从纹理化薄片突出，因此它们的末端示出为移动在一起或者至少稍微聚集。然而，如果示出的部分是上面详述的锁定层压材料的部分，那么末端被锁定在适当位置以阻止它们的聚集，转而赋予了高度的弯曲阻力，其中，每个结构都增加了抗弯能力。这样，从相对非刚性的薄片创建了刚性优越的层压件。当末端被钉牢时，由由此赋予层压的抗拉开或抗剥离能力实现强度的进一步大幅增加。
然后，可使用包括弯曲、牵引、冲压等方法的不同已知制造方法来形成这种锁定-层压材料。可通过加热层压件增强该制造方法以允许结构的末端50a通过软化的薄片移动至其新的角度关系(图13)，然后，当薄片冷却回到正常硬度使现在形成的层压板返回期望的刚度时被锁定在新的角度关系。
虽然上文的描述涉及三层和更多层层压件，但是应理解的是，可使用一个较硬的(纹理化后的)材料和一个较软的(可刺穿的)材料生成简单的双层层压件，使用上面描述的相同的辊子布置以将材料“锁定”在一起。
以上描述仅说明了本发明的某些优选实施方式。本发明并不限于上述示例。即，本领域的技术人员应明确且理解的是，可能或将来可能进行修改和变型来利用并实现本文所述的本发明的教导。权利要求的范围不应由示例中所述的优选实施方式限制，而是应对其给出与整体说明书一致的最宽泛目的解释。

Claims (30)

1.一种用于制造层压板的方法，包括：
在第一相对硬质材料的薄板的至少一个面设置表面纹理，所述表面纹理具有多个凸起的且大致尖状的结构；
使所述第一相对硬质材料的纹理化后的面与第二较软材料的面相接触；以及
使所述第一相对硬质材料的纹理化后的面与所述第二较软材料的面压合在一起，以使得所述尖状的结构中的至少一些进入所述第二较软材料以形成层压板。
2.根据权利要求1所述的方法，其中，所述第一相对硬质材料为金属。
3.根据权利要求1所述的方法，其中，所述第一相对硬质材料为钢。
4.根据权利要求1所述的方法，其中，所述第二较软材料为塑料、树脂、聚合物、泡沫、橡胶、木材或混合材料。
5.根据权利要求1所述的方法，其中，所述第二较软材料为可固化的材料。
6.根据权利要求5所述的方法，其中，所述压合步骤包括在部分固化状态下将所述第二较软材料施加至所述第一相对硬质材料，然后使所述第二较软材料固化。
7.根据权利要求1所述的方法，其中，所述第一相对硬质材料具有超过约80的布氏硬度，所述第二较软材料具有小于约30的布氏硬度。
8.根据权利要求1所述的方法，其中，通过使所述层压板通过辊子之间，来将所述第一相对硬质材料和所述第二较软材料压合在一起。
9.根据权利要求1所述的方法，其中，所述压合步骤至少使所述尖状结构的末端刺透所述第二较软材料，以使得所述末端在所述第二较软材料的第二面处突出。
10.根据权利要求9所述的方法，还包括使突出的末端变形以将其引导至所述第二较软材料的第二面之上、引导至所述第二较软材料的第二面上、或引导至所述第二较软材料的第二面中。
11.根据权利要求10所述的方法，其中，通过用辊子在所述末端上滚动，使所述末端变形。
12.根据权利要求10所述的方法，其中，通过所述第一相对硬质材料的第二板下压所述末端，使所述末端变形。
13.根据权利要求1所述的方法，还包括在将所述第一相对硬质材料和所述第二较软材料压合在一起之前，加热所述第一相对硬质材料和所述第二较软材料中之一或加热二者。
14.根据权利要求13所述的方法，其中，所述压合步骤包括在加热状态使所述第一相对硬质材料和所述第二较软材料至少部分地组合在一起，然后冷却组合后的材料。
15.根据权利要求13所述的方法，其中，所述第二较软材料被加热至软化状态，并且所述压合步骤包括在所述软化状态下使所述第二较软材料部分地组合至所述第一相对硬质材料，使所述第二较软材料冷却并且至少部分地硬化，然后进一步将所述第一相对硬质材料和所述第二较软材料压合在一起以形成所述层压板。
16.根据权利要求1所述的方法，其中，所述尖状结构具有钩形形状。
17.根据权利要求1所述的方法，其中，所述尖状结构预弯曲成钩形形状。
18.一种用于制造层压板的连续方法，包括：
从连续卷提供一定量的具有表面纹理的第一相对硬质材料的板，其中，所述表面纹理具有多个凸起的且大致尖状的结构；
使所述第一相对硬质材料的纹理化后的面与所述第二较软材料的面相接触；以及
将所述第一相对硬质材料的纹理化后的面与所述第二较软材料的面压合在一起，以使得所述尖状结构中的至少一些进入所述第二较软材料以形成层压板。
19.根据权利要求18所述的连续方法，其中，所述第二较软材料被连续地进给至所述第一相对硬质材料，并且在所述第一相对硬质材料和所述第二较软材料进给的下游将所述第一相对硬质材料和所述第二较软材料压合在一起。
20.根据权利要求18所述的连续方法，其中，所述第二较软材料被连续地滚制在所述第一相对硬质材料上。
21.根据权利要求18所述的连续方法，其中，在施加所述第二较软材料之前切割所述第一相对硬质材料。
22.根据权利要求18所述的连续方法，还包括在所述压合步骤之后将所述层压板切割成多个长度。
23.一种通过权利要求1-22中任一项所述的方法形成的层压板。
24.一种层压板，包括：
第一相对硬质材料，具有表面纹理，其中，所述表面纹理具有多个凸起的且大致尖状的结构；
第二较软材料，与所述第一相对硬质材料相配合，以使得所述尖状结构中的至少一些突出至所述第二较软材料中。
25.根据权利要求24所述的层压板，其中，所述尖状结构中的至少一些完全延伸通过所述第二较软材料。
26.根据权利要求25所述的层压板，其中，所述尖状结构的末端中的至少一些在所述第二较软材料上或在所述第二较软材料中被翻转，以便将所述第一相对硬质材料和所述第二较软材料保持在一起。
27.一种多层层压板，包括：
第一相对硬质材料的至少一个双面板，在所述双面板的两个面上具有表面纹理，所述表面纹理具有多个凸起的且大致尖状的结构；以及
第二较软材料的外层，设置在所述双面板的两侧上，所述第二较软材料与所述第一相对硬质材料相配合，以使得所述第一相对硬质材料的尖状结构中的至少一些突出至所述第二较软材料中。
28.根据权利要求27所述的多层层压板，还包括分别设置在所述外层中的每个的外部的、单面板的边界层，每个边界层都在其一个面上具有多个凸起的且大致尖状的结构；所述尖状结构进行设置，以便延伸至其相应的外层的至少一部分中。
29.根据权利要求27所述的多层层压板，其中，至少一个外层具有用于允许所述尖状结构进入的至少一个凹部。
30.根据权利要求27所述的多层层压板，其中，至少一个外层具有用于允许所述尖状结构进入的至少一个相对较薄的区域。
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