CN1303406A - 可热成型的聚丙烯泡沫材料片材 - Google Patents

可热成型的聚丙烯泡沫材料片材 Download PDF

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Publication number
CN1303406A
CN1303406A CN99806607A CN99806607A CN1303406A CN 1303406 A CN1303406 A CN 1303406A CN 99806607 A CN99806607 A CN 99806607A CN 99806607 A CN99806607 A CN 99806607A CN 1303406 A CN1303406 A CN 1303406A
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China
Prior art keywords
foam materials
foam
millimeters
sheet material
polymer
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Granted
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CN99806607A
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CN1118507C (zh
Inventor
M·H·图西姆
M·C·科乃尔
K·W·苏
C·P·克里斯坦森
C·P·帕克
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Dow Chemical Co
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Dow Chemical Co
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    • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
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    • B29C44/22—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of indefinite length consisting of at least two parts of chemically or physically different materials, e.g. having different densities
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Abstract

本发明公开了一种制造聚合物泡沫材料片材的方法,包括:(i)将包含至少一种聚丙烯聚合物和至少一种发泡剂的可发泡组合物在足以防止该组合物在离开模头之前发泡的压力、温度和挤出速率下挤过环状挤出模头,其条件足以形成一种密度至少为16千克/米3且不超过200千克/米3、开孔含量低于70%、圆周长至少为1米、且泡沫材料厚度至少为2毫米且不超过25毫米的泡沫材料管材,其中所述发泡剂的用量为0.2—4.5摩尔/千克聚合物,(ii)将泡沫材料冷却至该聚丙烯的熔化温度之下,然后(iii)将该泡沫材料管材沿着其半径切割成泡沫材料片材,其中该片材中至少70%重量的聚合物是在190℃下测定的熔体强度为25—60cN的聚丙烯。

Description

可热成型的聚丙烯泡沫材料片材
本发明的背景
本发明涉及挤制热塑性泡沫材料。美国临时专利申请№60/086944和60/089058在此作为参考完全并入本发明。
刚性泡沫材料片材具有各种用途，包括用于热成型场合如杯、碗、需要挺度以跨越长距离的非柔性场合，例如用于汽车头衬基材或包装甲板、盘等的原料。但某些用途要求耐热性比通常在聚乙烯和聚苯乙烯之类聚合物的泡沫材料时更高。聚氨酯泡沫材料是一种常用于这类场合的泡沫材料，但不如热塑性聚合物泡沫材料那些容易热成型。由可发泡聚丙烯珠粒制成的泡沫材料片材是得到具有较高耐热性的可热成型泡沫材料的一种方法，但该泡沫材料可能不具有某些场合所需的耐冲击性或弯曲和拉伸强度性能。此外，聚丙烯珠粒泡沫材料通常由比聚丙烯均聚物更柔韧的聚丙烯共聚物制成，因此相对由均聚物聚丙烯制成的泡沫材料具有较低的耐热性。
美国专利3637458公开了通过挤出工艺，由聚丙烯聚合物制成的微孔泡沫材料片材，但该工艺使用了较大量的发泡剂，结果所得产品可能不具有某些场合所需的密度、厚度、或挺度。
本发明的综述
在一个方面，本发明提供了一种制造聚合物泡沫材料片材的方法，包括：(ⅰ)将包含至少一种聚丙烯聚合物和至少一种发泡剂的可发泡组合物在足以防止该组合物在离开模头之前发泡的压力、温度和挤出速率下挤过环状挤出模头，其条件足以形成一种密度至少为16千克/米3且不超过200千克/米3、开孔含量低于70％、圆周长至少为1米、且泡沫材料厚度至少为2毫米至不超过25毫米的泡沫材料管材，其中所述发泡剂的用量为0.2-4.5摩尔/千克聚合物，(ⅱ)将泡沫材料冷却至该聚丙烯的熔化温度之下，然后(ⅲ)将该泡沫材料管材沿着其半径切割成泡沫材料片材，其中该片材中至少70％重量的聚合物是在190℃下测定的熔体强度为30-60cN的聚丙烯。
已经发现，本发明提供了一种由聚丙烯聚合物制备较密实的、闭孔或部分开孔的、可热成型的泡沫材料片材的方法。本发明的这些和其它优点在以下描述看来是显然的。
本发明的详细描述
通过本发明方法制成的泡沫材料片材容易成型为所需形状、构型或轮廓；具有足够刚性以防流挂并基本上保持其形状-即使暴露于通常车辆在热气候和/或直接日光条件下中所遇到的高温。该泡沫材料片材还具有良好的缓冲性能并具有良好的吸音和吸热作用。该泡沫材料的表面还优选相对没有在所需场合中损害其用途的裂痕、裂缝、折皱和其它表面缺陷。
该泡沫材料的开孔含量低于70％，更优选低于50％，更优选低于40％，最优选低于30％，更优选低于20％。开孔含量按照ASTM D2856-A来测定。闭孔泡沫材料的优点是较好的绝热性能和回弹性，而开孔泡沫材料的优点是较好的隔音作用、尺寸稳定性、和在热成型时的热传递效果。
按照ASTM D3575-93 Suffix W方法B进行测定，热塑性泡沫材料在热成型之前的密度至少为25千克/立方米，更优选至少32千克/立方米，最优选至少35千克/立方米；但优选不超过200千克/立方米，更优选不超过160千克/立方米，最优选不超过100千克/立方米。按照ASTM D3576，该泡沫材料的平均泡孔尺寸至少为0.1毫米，更优选至少0.5毫米，更优选至少0.75毫米，最优选至少1.0毫米；但优选不超过6毫米，更优选不超过5毫米，最优选不超过4毫米。最优选的密度和泡孔尺寸范围可根据该泡沫材料的组成和所需的物理性能而变化。例如，泡沫材料通常可通过增加密度或泡孔尺寸而制得更刚性。
该泡沫材料必须在机动车辆室顶由于阳光加热(最高125℃)所常遇到的高温下耐热扭曲且尺寸稳定。按照SAE 883，就膨胀和收缩两者而言，该泡沫材料的尺寸稳定性为约5％或更低，更优选约1％或更低。
该泡沫材料片材的横截面厚度至少为5毫米，更优选至少7毫米，最优选至少8毫米；但优选不超过25毫米，更优选不超过23毫米，最优选不超过20毫米。其宽度优选至少为1米，更优选至少1.1米，最优选至少1.2米；但优选不超过2.5米，更优选不超过2.2米，最优选不超过2.0米。
该泡沫材料容易热成型为所需形状、构型或轮廓。术语“可热成型”是指，该泡沫材料可在热和机械压力下，利用本领域已知的任何常规方式，根据需要热成型或制成不同的形状或轮廓。如果需要，可以将装饰层如机织热塑性纤维的织物层在热成型工艺过程中或之后热焊接到泡沫材料上。
泡沫材料的物理性能和耐热性可这样增强：在泡沫材料上形成或诱导形成基本上非发泡的皮，例如通过将塑料膜或片材层压到泡沫材料上，通过用塑料树脂将其涂覆；将泡沫材料的一个或多个表面加热至其玻璃化转变温度或熔点之上以使皮上的泡孔结构塌陷，或将任何前述方式组合使用。膜、片材或涂层可包含任何已知的热塑性树脂或热固性树脂。有用的热塑性树脂包括以上在构成该泡沫材料时所述的那些，且有用的热固性树脂包括聚氨酯和环氧树脂。
本文所用的术语“聚丙烯”是指丙烯单体单元至少为50％重量且在190℃下使用RheotensTM熔体拉伸装置测定的熔体强度为25-60cN的聚合物、以及该聚合物的混合物。熔化聚合物的熔体强度可通过在190℃下以0.030毫升/秒的速率用该装置将聚合物挤过一个直径2.1毫米且长度41.9毫米的毛细管模头而测定；然后将线材在恒定加速下拉伸，同时测定伸长率。聚丙烯的熔体强度优选至少为28cN，更优选至少30cN，最优选至少33cN；但优选不超过60cN，更优选不超过55cN，最优选不超过50cN。聚丙烯优选包含至少70％重量的丙烯单体单元。
采用RheotensTM熔体拉伸装置进行测定，用于本发明方法的聚丙烯的熔体伸长率至少为100％，更优选至少150％，最优选至少200％。在190℃下以0.030毫升/秒的速率，用该装置将聚合物挤过一个直径2.1毫米且长度41.9毫米的毛细管模头；然后将线材在恒定加速下拉伸，同时测定在特定伸长率下的拉伸力。按照ASTM D 1238条件L，丙烯聚合物材料优选具有约0.05-50dg/min，优选约0.1-20dg/min的熔体流速。由本发明方法制成的聚合物固体由至少70％重量，更优选至少80％重量，最优选至少85％重量的聚丙烯聚合物组成。
优选的树脂是支化的或轻微交联的聚丙烯树脂。支化(或轻微交联)可通过本领域一般已知的方法，如化学或辐射支化/光交联法而实现。美国专利4916198描述了在使用聚丙烯树脂制备最终聚丙烯树脂产品之前制成支化/轻微交联聚丙烯树脂的这样一种树脂、以及一种制备该聚丙烯树脂的方法，在此将其作为参考并入本发明。制备支化/轻微交联聚丙烯树脂的另一方法是，将化学化合物与聚丙烯树脂一起加入挤出机中，然后在挤出机中进行支化/轻微交联反应。美国专利4714716给出了该方法，在此将其作为参考并入本发明。辐射技术描述于美国专利5605936，在此也将其作为参考并入本发明。按照ASTM D2756-84，方法A，用于制备该泡沫材料的聚合物组合物的凝胶含量低于10％，更优选低于5％。
可加入该可发泡聚合物组合物的其它聚合物材料包括丙烯与可共聚烯属不饱和单体的共聚物。丙烯聚合物材料可仅由一种或多种丙烯均聚物、一种或多种丙烯共聚物、一种或多种丙烯均聚物和共聚物的共混物、或任何前述物质与非丙烯类聚合物的共混物构成。
合适的单烯属不饱和共聚单体包括烯烃、乙酸乙烯酯、丙烯酸甲酯、丙烯酸乙酯、甲基丙烯酸甲酯、丙烯酸、衣康酸、马来酸、马来酸酐和类似物。
特别有用的丙烯共聚物是丙烯与一种或多种非丙烯类烯烃的共聚物。丙烯共聚物包括丙烯与选自乙烯、C4-C101-烯烃和C4-C10-二烯的烯烃的无规、嵌段、和接枝共聚物。丙烯共聚物还包括丙烯与选自乙烯和C4-C81-烯烃的1-烯烃的无规三元聚合物。在同时具有乙烯和C4-C81-烯烃的三元聚合物中，乙烯含量优选为45％重量或更低。C4-C101-烯烃包括直链和支链C4-C101-烯烃，如1-丁烯、异丁烯、1-戊烯、3-甲基-1-丁烯、1-己烯、3,4-二甲基-1-丁烯、1-庚烯、3-甲基-1-己烯、和类似物。C4-C10-二烯的例子包括1,3-丁二烯、1,4-戊二烯、异戊二烯、1,5-己二烯、2,3-二甲基-1,3-己二烯和类似物。
适用于该可发泡组合物的非丙烯类聚合物包括包括高、中、低、和线型低密度聚乙烯、聚丁烯-1、乙烯/丙烯酸共聚物、乙烯/乙酸乙烯酯共聚物、乙烯/丙烯共聚物、苯乙烯/丁二烯共聚物、乙烯/苯乙烯共聚物、乙烯/丙烯酸乙酯共聚物、离聚物和类似物。如果需要，该可发泡聚合物组合物可包含其它的有用热塑性塑料，如高密度聚乙烯、氯化聚乙烯、EPDM橡胶(乙烯/丙烯/二胺共聚物)与聚乙烯的TPO混合物。
发泡剂可包括本领域已知的任何发泡剂，如具有有机和/或无机组成的化学发泡剂和物理发泡剂。该发泡剂可由有机试剂的共混物、无机试剂的共混物、或有机试剂与无机试剂的共混物组成。适用的无机发泡剂包括二氧化碳、氮气、氩气、水、空气、氮气和氦气。合适的有机发泡剂包括具有1-9个碳原子的脂族烃、和具有1-4个碳原子的卤化脂族烃。脂族烃包括甲烷、乙烷、丙烷、正丁烷、异丁烷、正戊烷、异戊烷、新戊烷、和类似物。在卤化烃中，氟化烃是优选的。氟化烃的例子包括氟甲烷、全氟甲烷、氟乙烷、1,1-二氟乙烷、1,1,1-三氟乙烷(R-143a)、1,1,1,2-四氟乙烷(R-134a)、五氟乙烷、全氟乙烷、2,2-二氟丙烷、1,1,1-三氟丙烷、全氟丙烷、全氟丁烷、全氟环丁烷。可用于本发明的部分卤化的氯代烃和氟氯烃包括氯甲烷、二氯甲烷、氯乙烷、1,1,1-三氯乙烷、1,1-二氯-1-氟乙烷(HCFC-141b)、1-氯-1,1-二氟乙烷(HCFC-142b)、1,1-二氯-2,2,2-三氟乙烷(HCFC-123)、和1-氯-1,2,2,2-四氟乙烷(HCFC-124)。完全卤化的氟氯烃包括三氯一氟甲烷(CFC-11)、二氯三氟甲烷(CFC-12)、三氯三氟甲烷(CFC-113)、二氯四氟乙烷(CFC-114)、一氯五氟丙烷、和二氯六氟丙烷。完全卤化的氟氯烃由于其臭氧消耗能力而不优选。化学发泡剂包括偶氮二甲酰胺、偶氮二异丁腈、苯磺酰肼、4,4-氧苯磺酰基-氨基脲、对甲苯磺酰基氨基脲、偶氮二甲酸钡、N,N’-二甲基-N,N’-二亚硝基对苯二甲酰胺、和三肼基三嗪。
在制备能够形成泡沫材料的聚合物凝胶时，加入聚合物熔体中的发泡剂的量为约0.2-4.0摩尔/千克聚合物，优选约0.3-3.0摩尔/千克聚合物，最优选约0.5-2.50摩尔/千克聚合物。此外，可以将成核剂加入发泡工艺中以控制泡沫材料泡孔的尺寸。优选的成核剂包括无机物质如碳酸钙、滑石、粘土、二氧化钛、硅石、硫酸钡、硬脂酸钙、硬脂酸钡、硅藻土、柠檬酸与碳酸氢钠的混合物、和类似物。成核剂的用量可以是约0.01-5重量份/100重量份聚合物树脂。优选范围为0.1-约3重量份。
还可在泡沫材料和发泡工艺中加入各种添加剂，如颜料、染料、抗氧化剂、酸捕捉剂、紫外线吸收剂、阻燃剂、加工助剂、挤出助剂、和类似物。
本发明工艺可这样进行：将热塑性聚合物加热形成塑化或熔化的聚合物材料，向其中加入物理发泡剂以形成可发泡的凝胶，冷却该可发泡凝胶，然后将该凝胶挤过模头以形成管状泡沫材料，进一步冷却至聚丙烯的结晶温度之下，然后沿着其半径纵切，形成一种宽度等于管圆周长的片材。发泡剂可通过本领域已知的任何方式，例如利用挤出机、混合器、搅拌机或类似设备，加入或混入塑料熔体中。在与发泡剂混合之前，将聚合物材料加热至该材料的玻璃化转变温度或熔点或更高。将发泡剂在足够高的压力下与塑料熔体混合，这样可基本上防止熔体膨胀且一般能够将发泡剂均匀分散在该熔体内。视需要，可将成核剂、稳定剂、着色剂和其它添加剂混入该聚合物熔体中。发泡剂和成核剂以及其它添加剂的加料速率可通过调节以获得较低密度的泡沫材料和较小的泡孔尺寸，这样可得到具有薄泡孔壁的泡沫材料。加入发泡剂之后，通常将可发泡凝胶冷却至较低温度以优化泡沫材料产品的物理性能。然后将该凝胶挤过一个具有所需形状的模头，到达一个具有较低压力的区域以形成泡沫材料产品。如果使用化学发泡剂，将其加入熔化的聚合物材料中，然后挤出或传送至具有较高温度的区域，在此发泡剂分解形成气体，通常为二氧化碳。熔化的聚合物材料/气体混合物膨胀形成泡沫材料。
美国专利4323528(在此将其作为参考并入本发明)涉及，利用储料挤出工艺来制备聚烯烃泡沫材料。该工艺包括：1)将热塑性材料与发泡剂混合形成一种聚合物凝胶；2)将该凝胶挤出到保压区，该区保持在不会使该混合物发泡的温度和压力下；该保压区具有一个用于确定开向低压(凝胶在该低压下发泡)区的孔的模头和一个密闭该模头孔的可开启门；3)定期打开该门；4)利用可移动撞锤，基本上同时将机械压力施用到凝胶上，将其从保压区经由模头孔喷射到具有较低压力的区；然后5)使射出的凝胶膨胀形成泡沫材料。
泡沫材料强度或挺度可通过挤出较薄的基本上非发泡板或型材而增强。在有或没有发泡剂的情况下，将挤出物或塑料熔体传送经过挤出模头内的不同孔并使其合并形成同时具有发泡和非发泡、或较少发泡部分的泡沫材料。在泡沫材料的挤出横截面中，非发泡树脂板或部分可以是规则或不规则图案。板或型材可相互交叉或非交叉。非发泡型材或板在泡沫材料内的可能横截面图案包括蜂窝状、环状、长方形或对角线网格图案。图1给出了具有长方形网格图案的板/型材和泡沫材料组合体，它具有发泡部分51和非发泡部分52。
通过用热线切割泡沫材料并随后重组或合并这些切断的泡沫材料片，还可制备出具有发泡和非发泡部分的挤制结构，这样它们就热焊接在一起。优选的是，在用热线切断泡沫材料之后，立即进行热焊接。在合并这些切断的泡沫材料片之后，将热施用到泡沫材料上，使邻近该线的泡沫材料的泡孔结构崩塌，并在泡沫材料内形成非发泡的板或型材。
通过将发泡和非发泡型材或层相互层压成一种交替构型以形成整体结构，还可制造出具有发泡和非发泡部分的结构。这些型材或层可通过热焊接或粘附而层压到一起。
泡沫材料的物理性能和耐热性可通过加入填料形式的有机或无机材料颗粒或纤维而增强。这些颗粒或纤维可在制造过程中加入能够形成泡沫材料的组合物。有用的材料包括炭黑颗粒、粘土颗粒、碳或石墨纤维、聚丙烯纤维、聚酯纤维、和尼龙纤维、玻璃纤维、和丙烯腈纤维。泡沫材料的物理性能和耐热性还可通过向泡沫材料上层压包含这些颗粒和/或纤维的非发泡膜/片材层或涂层而增强。纤维可以是任何长度，短(原纤)或长。它们可作为织物或半固化片无规分散或机织或放置在一起。
可以使用本领域已知的粘合剂，将本发明泡沫材料相互粘附或粘附到其它材料上。可用的粘合剂包括热固性粘合剂如聚氨酯树脂和环氧树脂、和热塑性粘合剂如聚乙烯、聚丙烯、乙烯共聚物、丙烯共聚物、和类似物。可用的粘合剂介绍于美国专利5460870和5670211。粘合剂可通过本领域已知的任何方式，例如通过喷射、涂布、或以膜形式进行施用。优选的粘合剂为热塑性的，这样成本较低且可能回收。粘合剂的存在对本发明并不重要。
可以将一层或多层装饰材料如毛毡或织物施用到该泡沫材料片材的一个或多个表面上。该层可以是本领域已知的任何种类。商业上常用的是毛毡或机织织物。有用的织物包括机织聚酯、尼龙、和聚丙烯纤维的织物。毛毡或织物层优选由与泡沫材料相同或类似的聚合物材料构成。该毛毡或织物层可通过本领域已知的任何方式，如热焊接、粘合剂膜、或粘合剂液体或涂料而粘附到泡沫材料上。优选的装饰层是无需利用粘合剂而热焊接到核层上的热塑性纤维的机织织物。热焊接是指，将织物层加热使得纤维变粘或有粘性且能够粘附到核层上而无需利用粘合剂。如果在热成型过程中或当核层处于高温时施用到核层上，那么织物层也可热焊接到核层上。
该泡沫材料容易热成型为所需形状、构型或轮廓。术语“可热成型”是指，该泡沫材料可在热和机械压力下，利用本领域已知的任何常规方式热成型或制成不同的形状或轮廓。通常，该泡沫材料在热和压力下压制形成类似于机动车辆室顶(该泡沫材料位于其下方)的形状和轮廓的异型片材。如果需要，可以将装饰层如机织热塑性纤维的织物层在热成型工艺中热焊接到泡沫材料上。通过本发明方法制成的泡沫材料片材优选可在130-170℃的温度下和34-650kPa的压力下模塑。
泡沫材料的物理性能和耐热性可这样增强：在泡沫材料上形成或诱导形成基本上非发泡的皮，例如通过将塑料膜或片材层压到泡沫材料上，通过用塑料树脂将其涂覆；将泡沫材料的一个或多个表面加热至其玻璃化转变温度或熔点之上以使皮上的泡孔结构塌陷，或将任何前述方式组合使用。膜、片材或涂层可包含任何已知的热塑性树脂或热固性树脂。有用的热塑性树脂包括以上在构成该泡沫材料时所述的那些，且有用的热固性树脂包括聚氨酯和环氧树脂。
以下实施例用于说明本发明，而不应看作以任何方式限定其范围。
说明性实施方案
实施例1
生产出挤制聚丙烯泡沫材料片材。用于生产该泡沫材料的装置包括串联的挤出机、混合器、冷却器、和环状挤出模头。将聚合物以颗粒形式加料到挤出机中，在此将其与添加剂混合形成聚合物熔体。所用的聚丙烯(PP)聚合物是PF-814(来自Montell)。PF-814是一种高熔体强度的PP树脂，通过测试方法ASTM D-1238测定的熔体流速为3dg/min。聚丙烯聚合物的加料速率为1000磅/小时(454千克/小时)。将聚丙烯树脂共混物与0.25磅/100磅聚合物(pph)的滑石进行混合。另外，每100磅聚合物中加入0.1磅Irganox 1010稳定剂(来自Ciba-Geigy Corporation)和0.1磅Ultranox 626(来自GESpecialty Chemcials,Inc.)。挤出机条件为170℃(在挤出机的加料端)至220℃(在挤出机的传送端)。将聚合物和添加剂传送到混合器中，在此在压力下向其中加入5份异丁烷发泡剂/100份聚合物，形成一种可发泡的凝胶。将该可发泡凝胶冷却至165℃，然后在压力下传送至模头，在此它在20英寸直径心轴附近，由5英寸直径的环状孔膨胀至具有较低压力的区，形成一种管状泡沫材料片材产品。该管状片材随后劈开成平整片材。
该泡沫材料的厚度为5mm(毫米)且宽度为1600毫米，开孔含量为1.6％，密度为2.7磅/立方英尺(pcf)(43.2千克/立方米(kgm))，且平均泡孔尺寸为1.7毫米。该泡沫材料较刚性，在支撑其自身重量时不流挂，且可热成型。该泡沫材料按照美国专利5527573所述的可发泡性系数为5.3。
实施例2
在实施例1所公开的装置上，生产出另一挤制聚丙烯泡沫材料片材，其中采用与实施例1相同的发泡剂含量和加载量和基本上相同的加工条件，但模头间隙开口较大且接取速度较慢。
该泡沫材料的厚度为9毫米且宽度为1600毫米，开孔含量低于2％，密度为2.4pcf(38kgm)，且平均泡孔尺寸为1.7毫米。该泡沫材料较刚性，且在支撑其自身重量时不流挂。该泡沫材料的可发泡性系数为4.7。
实施例3
在实施例1所公开的装置上，生产出另一挤制丙烯共聚物泡沫材料片材，其中采用与实施例1相同的发泡剂含量和加载量和基本上相同的加工条件。
该泡沫材料的厚度为7毫米且宽度为1600毫米，开孔含量为19％，密度为2.9pcf(46.1kgm)，且平均泡孔尺寸为1.75毫米。该泡沫材料较刚性，在支撑其自身重量时不流挂，且可热成型。该泡沫材料按照美国专利5527573所述的可发泡性系数为5.8。
实施例4
在实施例1所公开的装置上，生产出另一挤制聚丙烯泡沫材料片材，其中采用相同的发泡剂和添加剂并添加硬脂酸钙粉末用于附加泡孔成核。将聚丙烯聚合物以990磅/小时(449千克/小时)的速率与0.42pph滑石、0.3pph Ultranox 815P稳定剂(来自GE SpecialtyChemcials)、0.3pph硬脂酸钙一起加料到挤出机中。将该塑化凝胶混合物与3.9pph异丁烷在压力下混合，冷却至161℃，然后传送至环状模头，在此将其膨胀至具有较低压力的区，在16”直径冷却心轴上拉伸形成一种管状泡沫材料片材产品。该管状片材随后劈开成平整片材。
该泡沫材料的厚度为7毫米且宽度为1290毫米，开孔含量为20.4％，密度为3.3pcf(52.9kgm)，且平均泡孔尺寸为3.6毫米。该泡沫材料较刚性，在支撑其自身重量时不流挂，且可热成型。该泡沫材料按照SAE J949所述方法测定的断裂弯曲强度值为175psi(1.21MPa)，且可发泡性系数为13.6。
实施例5
在实施例1所公开的装置上，生产出另一挤制聚丙烯泡沫材料片材，其中采用相同的发泡剂和添加剂并添加硬脂酸钙粉末用于附加泡孔成核。将聚丙烯聚合物以1380磅/小时(626千克/小时)的速率与0.30pph滑石、0.21pph Ultranox 815P稳定剂(来自GE SpecialtyChemcials)、0.3pph硬脂酸钙一起加料到挤出机中。将该塑化凝胶混合物与3.9pph异丁烷在压力下混合，冷却至161.5℃，然后传送至环状模头，在此将其膨胀至具有较低压力的区，在20英寸直径冷却心轴上拉伸形成一种管状泡沫材料片材产品。该管状片材随后劈开成平整片材。
该泡沫材料的厚度为10.9毫米且宽度为1600毫米，开孔含量为2.2％，密度为3.4pcf(54.5kgm)，且平均泡孔尺寸为5.2毫米。该泡沫材料较刚性，在支撑其自身重量时不流挂，且可热成型。该泡沫材料按照SAE J949所述方法测定的断裂弯曲强度值为141psi(1MPa)，且可发泡性系数为20.3。
实施例6
由75％聚丙烯PF-814(来自Montell)和25％AFFINITYTM PL-1880聚乙烯(来自Dow Chemical Company)的共混物生产出挤制泡沫材料片材。PL-1880是一种聚乙烯树脂，其熔体指数为1.0dg/min，密度为0.9020克/毫升，且I10/I2为9.0。在实施例1所公开的装置上生产该泡沫材料片材。将聚合物共混物以1000磅/小时(454千克/小时)的速率与0.4pph滑石和0.3pph Ultranox 815P稳定剂(来自GESpecialty Chemcials)一起加料到挤出机中。将该塑化凝胶混合物与6.0pph异丁烷在压力下混合，冷却至157℃，然后传送至环状模头，在此将其膨胀至具有较低压力的区，在20英寸直径冷却心轴上拉伸形成一种管状泡沫材料片材产品。该管状片材随后劈开成平整片材。
该泡沫材料的厚度为7毫米且宽度为1600毫米，开孔含量为14.4％，密度为3.6pcf(57.7kgm)，且平均泡孔尺寸为3.4毫米。该泡沫材料较刚性，在支撑其自身重量时不流挂，且可热成型。该泡沫材料按照SAE J949所述方法测定的断裂弯曲强度值为72psi(0.5MPa)，且可发泡性系数为14.0。
实施例7
由75％聚丙烯PF-814(来自Montell)和25％AFFINITYTM PL-1880聚乙烯(来自Dow Chemical Company)的共混物生产出挤制泡沫材料片材。PL-1880是一种聚乙烯树脂，其熔体指数为1.0dg/min，密度为0.9020克/毫升，且I10/I2为9.0。在实施例1所公开的装置上生产该泡沫材料片材。将聚合物共混物以1000磅/小时(454千克/小时)的速率与0.4pph滑石和0.3pph Ultranox 815P稳定剂(来自GESpecialty Chemcials)一起加料到挤出机中。将该塑化凝胶混合物与6.0pph异丁烷在压力下混合，冷却至157℃，然后传送至环状模头，在此将其膨胀至具有较低压力的区，在20英寸直径冷却心轴上拉伸形成一种管状泡沫材料片材产品。该管状片材随后劈开成平整片材。
该泡沫材料的厚度为9.8毫米且宽度为1600毫米，开孔含量为5.8％，密度为2.7pcf(43.3kgm)，且平均泡孔尺寸为4.5毫米。该泡沫材料较刚性，在支撑其自身重量时不流挂，且可热成型。该泡沫材料按照SAE J949所述方法测定的断裂弯曲强度值为70psi(0.5MPa)，且可发泡性系数为13.0。
实施例8
由75％聚丙烯PF-814(来自Montell)和25％AFFINITYTM PL-1880聚乙烯(来自Dow Chemical Company)的共混物生产出挤制泡沫材料片材。PL-1880是一种聚乙烯树脂，其熔体指数为1.0dg/min，密度为0.9020克/毫升，且I10/I2为9.0。在实施例1所公开的装置上生产该泡沫材料片材。将聚合物共混物以1200磅/小时(545千克/小时)的速率与0.4pph滑石和0.3pph Ultranox 815P稳定剂(来自GESpecialty CheMcials)一起加料到挤出机中。将该塑化凝胶混合物与6.0pph异丁烷在压力下混合，冷却至156℃，然后传送至环状模头，在此将其膨胀至具有较低压力的区，在20英寸直径冷却心轴上拉伸形成一种管状泡沫材料片材产品。该管状片材随后劈开成平整片材。
该泡沫材料的厚度为14.6毫米且宽度为1600毫米，开孔含量为3.3％，密度为2.6pcf(41.7kgm)，且平均泡孔尺寸为3.2毫米。该泡沫材料较刚性，在支撑其自身重量时不流挂，且可热成型。该泡沫材料按照SAE J949所述方法测定的断裂弯曲强度值为58psi(0.4MPa)。该泡沫材料的可发泡性系数为9.5。
实施例9
将实施例8的泡沫材料片材层压上1.6密耳(0.04毫米)厚的多层膜。该膜由两层组成：a)乙烯-丙烯酸共聚物/线型低密度聚乙烯共混物(60/40)；b)均聚物聚丙烯。粘合剂层a)占膜厚度的70％。将该膜层压到泡沫材料的一面。层压之后，将膜/泡沫材料结构切成3英寸×12英寸截面并按照SAE Test J949测试弯曲强度。所得结构需要大于25牛顿才能弯曲1英寸(25.4毫米)。该泡沫材料的可发泡性系数为9.5。将该泡沫材料切割并模塑成车辆头衬的所需型材，然后将一层装饰织物粘附到其上。将该头衬安装在邻近车辆室顶下方的车辆中，然后利用合适的粘合剂粘附其上。
实施例10
将实施例5的泡沫材料片材层压上如实施例9所述的1.6密耳(0.04毫米)厚的多层膜。将该膜层压到泡沫材料的一面。层压之后，将膜/泡沫材料结构切成3英寸×12英寸截面并按照SAE Test J949测试弯曲强度。该泡沫材料的可发泡性系数为20.3。所得结构需要大于45牛顿才能弯曲1英寸(25.4毫米)。实施例5的泡沫材料需要20牛顿来弯曲1英寸(25.4毫米)。
实施例11
将实施例7的泡沫材料片材层压上如实施例9所述的1.6密耳(0.04毫米)厚的多层膜。将该膜层压到泡沫材料的一面。层压之后，将膜/泡沫材料结构切成3英寸×12英寸截面并按照SAE Test J949测试弯曲强度。该泡沫材料的可发泡性系数为13.0。所得结构需要大于14牛顿才能弯曲1英寸(25.4毫米)。
此外发现，为了由以上实施例所述的聚合物和发泡剂组合物制备出可接受的泡沫材料，熔化聚合物和发泡剂在进入模头之前的压力优选至少为3.0MPa，更优选3.3MPa，最优选3.4MPa，这样可保持发泡剂溶解在熔化聚合物中。该压力通过安装在环状模头之前的标准压力计来测定。每个实施例的测定压力列于表1。
表1
    实施例号 模头之前的凝胶压力(MPa)
    1     5.2
    2     5.3
    3     5.4
    4     3.5
    5     3.8
    6     4.8
    7     3.9
    8     4.4

Claims (25)

1．一种制造聚合物泡沫材料片材的方法，包括：(ⅰ)将包含至少一种聚丙烯聚合物和至少一种发泡剂的可发泡组合物在足以防止该组合物在离开模头之前发泡的压力、温度和挤出速率下挤过环状挤出模头，其条件足以形成一种密度至少为16千克/米3且不超过200千克/米3、开孔含量低于70％、圆周长至少为1米、且泡沫材料厚度至少为2毫米且不超过25毫米的泡沫材料管材，其中所述发泡剂的用量为0.2-4.5摩尔/千克聚合物，(ⅱ)将泡沫材料冷却至该聚丙烯的熔化温度之下，然后(ⅲ)将该泡沫材料管材沿着其半径切割成泡沫材料片材，其中该片材中至少70％重量的聚合物是在190℃下测定的熔体强度为25-60cN的聚丙烯。
2．根据权利要求1的方法，其中该片材中至少80％重量的聚合物是在190℃下测定的熔体强度为25-60cN的聚丙烯。
3．根据权利要求1的方法，其中所述泡沫材料的密度至少为32千克/米3。
4．根据权利要求1的方法，其中所述片材的宽度至少为1.1米且厚度至少为5毫米。
5．根据权利要求1的方法，其中所述片材的宽度至少为1.1米且厚度至少为7毫米。
6．根据权利要求1的方法，其中所述片材的宽度至少为1.1米且厚度至少为8毫米。
7．根据权利要求1的方法，其中所述片材的宽度至少为1.2米且厚度至少为5毫米。
8．根据权利要求1的方法，其中所述片材的宽度至少为1.2米且厚度至少为7毫米。
9．根据权利要求1的方法，其中所述片材的宽度至少为1.2米且厚度至少为8毫米。
10．根据权利要求1的方法，其中所述发泡剂为异丁烷。
11．根据权利要求1的方法，其中所述发泡剂是有机发泡剂与无机发泡剂的混合物。
12．根据权利要求1的方法，其中所述有机发泡剂选自正丁烷、异丁烷、丙烷和乙醇。
13．根据权利要求11的方法，其中所述有机发泡剂选自正丁烷、异丁烷、丙烷和乙醇。
14．根据权利要求11的方法，其中所述无机发泡剂选自二氧化碳、氩气、水和氮气。
15．根据权利要求1的方法，其中所述发泡剂是一种无机发泡剂，选自二氧化碳、氩气、水和氮气。
16．根据权利要求1的方法，其中所述聚丙烯的熔体流速低于10dg/min。
17．根据权利要求1的方法，其中将所述可发泡组合物在足以形成具有发泡和非发泡部分的片材的条件下与不可发泡的熔化聚合物共挤出。
18．根据权利要求1的方法，其中所述泡沫材料的平均泡孔尺寸为0.1-6.0毫米。
19．根据权利要求1的方法，其中所述泡沫材料的平均泡孔尺寸为0.5-6.0毫米。
20．根据权利要求18的方法，其中所述泡沫材料的平均泡孔尺寸至少为0.75毫米。
21．根据权利要求19的方法，其中所述泡沫材料的平均泡孔尺寸至少为1.0毫米。
22．根据权利要求1的方法，其中该片材中至少75％的聚合物是在190℃下测定的熔体强度为25-60cN的聚丙烯。
23．根据权利要求1的方法，其中该片材中至少95％的聚合物是在190℃下测定的熔体强度为25-60cN的聚丙烯。
24．根据权利要求1的方法，其中可发泡组合物在挤出之前的压力至少为3MPa。
25．根据权利要求1的方法，其中所述泡沫材料的开孔含量低于50％。
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