CN1726368A - 绝热泡沫型材 - Google Patents

绝热泡沫型材 Download PDF

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CN1726368A
CN1726368A CNA2003801057384A CN200380105738A CN1726368A CN 1726368 A CN1726368 A CN 1726368A CN A2003801057384 A CNA2003801057384 A CN A2003801057384A CN 200380105738 A CN200380105738 A CN 200380105738A CN 1726368 A CN1726368 A CN 1726368A
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foam
forming profiles
web
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CN100453879C (zh
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约翰·托蒂
戴维·安东尼·奥利弗
托马斯·麦凯布
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Kingspan Holdings IRL Ltd
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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
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • B29C44/12—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
    • B29C44/14—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements the preformed part being a lining
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
    • F16L59/00—Thermal insulation in general
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    • B29C44/1228—Joining preformed parts by the expanding material
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    • F16L59/022—Shape or form of insulating materials, with or without coverings integral with the insulating materials comprising a single piece or sleeve, e.g. split sleeve, two half sleeves with a single slit
    • F16L59/023—Shape or form of insulating materials, with or without coverings integral with the insulating materials comprising a single piece or sleeve, e.g. split sleeve, two half sleeves with a single slit with a hinge opposite the slit
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
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    • F16L59/00—Thermal insulation in general
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C33/00—Moulds or cores; Details thereof or accessories therefor
    • B29C33/34—Moulds or cores; Details thereof or accessories therefor movable, e.g. to or from the moulding station
    • B29C33/36—Moulds or cores; Details thereof or accessories therefor movable, e.g. to or from the moulding station continuously movable in one direction, e.g. in a closed circuit
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Abstract

管道绝热型材(1)包括具有内部面层带材(3)和外部面层带材(4)的大体均匀横截面的大致圆筒形中空酚醛泡沫体(2)。酚醛泡沫体(2)被纵切以提供两型材半体，型材半体能被打开以便包裹管道来使管道绝热。型材半体在一侧通过外部面层带材相连，型材半体的相对端在另一侧与内部面层带材(3)面对。内部面层带材(3)可以是纸，外部面层带材(4)可以是铝箔。用于制造细长成形酚醛型材的装置包括使外部面层带材(4)形成圆筒形的外部模具(10)和使内部面层带材(3)形成圆筒形的内部心棒(11)，内部面层带材的圆筒直径小于外部面层带材的圆筒直径。面层带材(3，4)中限定中空内芯，液体泡沫反应物(20)通过注入器注入其中。

Description

绝热泡沫型材
技术领域
本发明涉及酚醛绝热泡沫型材、特别是适于管道绝热的酚醛绝热泡沫型材的加工。
背景技术
历史上，当在失火条件下低排烟和自熄火能力至关重要时，酚醛树脂曾经是优选的热固塑性材料。一种这样的应用是建筑绝热和管道绝热，其中酚醛泡沫既在使用中提供绝热又在失火期间有良好的表现。
目前，这种酚醛泡沫管道型材是通过生产巨大的泡沫块来制备的，该泡沫块随后被专门的切割机械切割成多种管道型材长度。现代计算机分析技术使从这种泡沫块非常高效地切割出型材形状成为可能，但商业现实是在实践中从这种泡沫块再生出多于60％的好材料是很少见并困难的。
因此，常规技术产生了大量废料泡沫-通常超过该泡沫块的40％。这些废料泡沫不能容易地作为原材料再次使用，原因在于它是不可逆地交联的。在其它过程中将它作为原材料再次使用是可能的，但是，很少在一个地方有足够多的废料泡沫产生而值得这么做。因此，该废料通常简单地用于土地填筑或被焚烧。这两种技术都会引起费用，并且在大多数国家土地填筑都是不受欢迎的并通常会被格外地征税或被淘汰。焚烧场所通常在当地都是不受欢迎的，并且将来可能会更难处理。
迄今为止多年来都在寻求用于制造适于管道型材的酚醛绝热泡沫型材的块料法的替代方法，但都没有获得实际的商业成果。铸模能够单独使用或在圆盘传送带中使用，但是该过程缓慢并且随着产量的增加而变得资本密集。模制过程仅对于诸如肘管或弯管的少数型材是真正可行的。
发明内容
根据本发明，提供了一种用于连续生产细长酚醛泡沫绝热成形型材的方法，包括以下步骤：
提供第一面层带材(facing web)；
提供第二面层带材；
将液体酚醛泡沫反应物灌注到所述两面层带材之间；
使面层带材定形，以使得面层带材和泡沫混合物符合预期轮廓形状；
加热内部和外部面层带材；以及
支撑所述面层带材，以将泡沫保持在预期形状，直到泡沫已经固化成成形轮廓型材。
在一个实施例中，内部和外部面层带材都被加热到介于45℃到85℃之间的温度。内部和外部面层带材可以被加热到介于50℃到70℃之间的温度。
在一个实施例中，内部面层带材由心棒定形，该心棒可以被加热。该心棒可以是通过使热交换流体在其中循环而被加热的中空心棒。
在一个实施例中，心棒至少局部地涂有诸如特氟隆的减摩剂。
在一个实施例中，外部面层带材由模具定形。该模具可以被加热。该模具可以通过辐射热加热。
在一个实施例中，本方法包括后固化细长泡沫绝热成形型材的步骤。
该成形型材可以在介于20℃到85℃之间的温度下后固化4到48小时的时间。该成形型材可以在介于50℃到85℃之间的温度下后固化4到48小时的时间。
在一个实施例中，本方法包括将该成形型材切割成预期长度段。该成形型材可以在线切割成预期长度。
细长泡沫绝热成形型材可以包括大体均匀截面的中空泡沫体。该成形型材可以是曲线形的，优选地是圆柱形的。
该成形型材可以是直线形的。
该泡沫体可以包括用于管道的绝热体。可选地该泡沫体包括导管或用于该导管的绝热体。该泡沫体可以包括管支架。
在一个实施例中，内部面层带材是诸如铝箔的金属箔、纸、玻璃、热塑薄膜或以上两种或多种的组合。
外部面层带材可以诸如铝箔的金属箔、纸、玻璃、热塑薄膜或以上两种或多种的组合。
本发明还提供一种只要是用本发明的方法生产的细长泡沫绝热成形型材。
本发明的另一方面提供一种包括大体均匀截面的中空酚醛泡沫体的细长成形型材，该泡沫体具有外部面层带材和内部面层带材。
该泡沫体可以是曲线形的，诸如大体圆柱形的。可选地，该泡沫体可以是直线形的。
在一个实施例中，该泡沫体被纵向地被切成型材部分，用于包裹物体。该型材部分可以在一侧上通过外部面层带材相连。在一个实施例中，型材部分的相对端在相反侧上与内部面层带材相面对。
该泡沫体可以包括用于管道的绝热体，或者可以包括导管或用于它的绝热体或管支架。
根据本发明的另一方面，提供一种用于连续生产细长酚醛泡沫绝热成形型材的装置，该细长酚醛泡沫绝热成形型材包括内部面层带材、外部面层带材以及两面层带材之间的绝热泡沫，该装置包括用于定形内部面层带材的心棒和用于定形外部面层带材的模具，其中心棒至少局部地涂有减摩材料。优选地，该心棒基本上完全涂有减摩材料。减摩材料可以是特氟隆。
根据本发明的又一方面，提供一种用于连续生产细长酚醛泡沫绝热成形型材的装置，该细长酚醛泡沫绝热成形型材包括内部面层带材、外部面层带材以及两面层带材之间的绝热泡沫，该装置包括机架、用于定形内部面层带材的心棒和用于定形外部面层带材的模具，其中，心棒装配到可移动支架，该支架又运行在支撑轨道中用于心棒转换。该轨道支撑在按可调整的方式安装到机架的心棒安装台上。
根据本发明，提供了一种使用酚醛泡沫反应物制造具有连续轮廓的绝热酚醛泡沫管道型材的方法。
术语“酚醛泡沫反应物”是指这样一种树脂，其主要基于苯酚甲醛，并利用稳定剂、增塑剂、发泡剂、表面活化剂、催化剂、和/或引发剂体系和包括聚醚或聚酯多元醇和/或异氰脲酸酯在内的其他可能组分来生产闭室泡沫塑料。
本方法包括以下步骤：连续喂入面层带材；将酚醛泡沫预聚物灌入这些面层带材之间；以及通过连续地进入双链定型加热传送带而将型材成形，该传送带使预聚物能够固化为成形型材。
本发明提供了一种用于连续生产具有所需的惊人的良好低热传导率特性保持力的酚醛泡沫型材的方法。由于没有生产出废料型材，该方法产生很底的固有废料和料头率，废料被限于切割刀片宽度以及机器启动时或遇到加工问题时偶然产生的料头部分(由于该方法能轻易地被停止和启动，这些废料很自然是有限的)和。
本发明提供了一种用于连续生产酚醛泡沫绝热管道型材且具有最少的废料的方法，该方法包括以下步骤：连续喂入面层带材；将酚醛泡沫预聚物灌入这些面层带材之间；以及通过连续地进入双皮带型成形加热传送带而将型材定型，该传送带使预聚物能够固化为成形型材。
内部心棒和外部模具部分都可以被加热，以确保酚醛泡沫绝热体在商业实用的时间内以超过2米/分钟、优选地超过4米/分钟的速率充分固化。
内部心棒和外部模具部分能够生产各种尺寸的型材或具有相似的连续轮廓的酚醛泡沫绝热型材。
各种酚醛树脂和催化剂体系可以用于通过这种方法生产连续的管道型材或具有其它轮廓的绝热型材。
管道型材可以在50℃到85℃之间的温度下后固化，以生产具有良好的尺寸稳定性和稳定的热传导率的产品。
可以使用包括铝箔、纸、玻璃、热塑薄膜或这些的组合的各种不同的面层材料。
附图说明
参考附图从下面以示例形式给出的说明中可以更清楚地了解本发明，附图中：
图1是根据本发明的酚醛泡沫绝热型材的剖视图；
图2是图1的绝热型材局部打开用于装配到管道周围的剖视图；
图3是用在生产图1的绝热型材中的装置的示意图；
图4是图3的装置的细节的透视图；
图5是该装置的被加热的模具细节的透视图；
图6是模具细节的俯视图；和
图7是显示心棒装配的示意性剖视图。
具体实施方式
参考附图，首先参考图1和图2，在该情况下以管道绝热型材1的形式示出了一种细长成形酚醛型材。该管道绝热型材包括基本上均匀截面的大体圆柱形中空酚醛泡沫体2，该截面由内部面层带材3和外部面层带材4围成。应注意，在该情况下，酚醛泡沫体2纵向地被切开以形成两个型材半体，这两个型材半体可以打开成如图2所示那样以方便包裹管道从而使管道绝热。这两个型材半体通过外部面层带材4在一侧上相连，而型材半体的相对端与内部面层带材3在另一侧上相面对。外部面层带材4在型材半体间的接合处形成铰链部4a。内部面层带材3可以是诸如纸的任何合适材料，另一面层带材4可以是诸如铝箔的任何合适材料。
现在参考图3到图6，示出了一种用在制造本发明的细长成形酚醛型材中的装置。该装置包括：用于使外部面层带材4形成为预期形状(在本例中为圆筒形)的外部模具10；和用于使内部面层带材3形成为预期形状(在本例中也是圆筒形)的内部心棒11，其直径小于外部面层带材4所限定的圆筒的直径。面层带材3、4在其间限定了中空内芯，液体泡沫反应物20通过注入器25注入到该中空内芯中。
在进入模具10之前将外部面层带材4导入穿过定型器27。模具10包括如图4到图6那样互连的多个模具段28。模具段28通过辐射加热而被加热到介于45℃到85℃之间的温度，优选地介于50℃到70℃之间。类似地，定型器11通过使用诸如热水的热交换介质而被加热到相同温度，该热交换介质经过定型器11在入口/出口30之间进行循环。
心棒/定型器11具有向上突出翅片35，过量内部面层带材3A被引导到该翅片35上。翅片35用于将心棒11安装到机器中。过量内部面层带材3A由引导轮40引导，而过量外部面层带材4A由引导轮41引导。
心棒优选地至少局部涂有减摩材料，诸如作为杜邦的商标的特氟隆。这样具有减少作用在移动面层带材和固定心棒之间的摩擦的作用。这种减摩措施非常重要，原因是摩擦能使内部面层带材比外部面层带材移动得更慢。处于两面层带材之间的正膨胀的泡沫以及两面层带材的不同运动可能导致泡沫单元变成细长而对泡沫的性能产生不利影响。
参考图7，为了方便心棒转换，通过沿心棒长度方向使用一系列轮架41将心棒11定位在金属轨道40中。轨道40沿机器的长度方向延伸。轨道40支撑在心棒安装台45上，该心棒安装台45又通过可调整的安装托架47安装到机架46。
将每个心棒的中心线设计成相对于轨道具有完全相同的位置关系，以便当更换心棒时，下一个心棒的中心点相对于模具28正确地排列。心棒11的位置的任何改变都可以通过移动其中搁有心棒的轨道40来实现，从而同时改变所有心棒的有效位置。
本发明提供了连续生产成形绝热酚醛泡沫型材且废料最少的问题的解决方案。
在本发明中，在正要将预聚混合物灌注到“外部”面层带材4上之前，引入形成面层带材3、4的带材并将之定形。“外部”面层带材4卷曲以装配到被连续旋转的刚性模具段28内，该模具段28在中心轴线两侧的双链系统上旋转。这些模具段28形成管道型材绝热轮廓的外侧的形状，并以短段形式设置以易于更换，从而使不同外径或不同轮廓形状成为可能。模具段28可以是实心或中空材料的，并且可以具有电或液流加热装置，或可以被远红外、传导或气流装置分开加热。通常，模具段28可以由木头、塑料或金属形成。模具段28的上半部分夹住外部面层带材4的过量部分4A，提供沿机器的中心轴线推动过量部分4A的牵引力。将“内部”面层带材3绕中心定形心棒11连续地卷曲，该心棒11沿机器的中心轴线的一部分延伸，不与外部链一起移动，而是保持静止。中心心棒11可以被加热，通常通过使用液体(水或油)循环系统加热。
苯酚甲醛树脂与适当的表面活性剂、增塑剂、发泡剂体系混合，并在混合物通过喷嘴25正要灌注到被定形成用于持有该混合物的连续移动的面层带材4上之前与快速催化剂混合。上述全体被连续地喂入到模具28的双链系统之间，以便外部面层带材4被保持为外部模具段的形状，并以与这些模具段相同的速度移动，而内部面层带材3在内部加热心棒11上滑动。沿机器的中心轴线几米、在树脂混合物已经充分聚合以至可以自支撑的地点，心棒段11结束。外部型材的最后聚合和局部固化随后沿机器的中心轴线继续，并且在管道型材的外侧充分固化的地点，将模具段28从双链上分离并使之沿机器的外部返回本过程的起点。如果模具段28不是自加热的，则它们可以正好在机器的前面通过沿外侧放置的散热器加热。
从机器连续地露出的局部固化的型材被切成适于搬运的适当长度(通常为1米)的段，如上所述连续地纵切以允许包在管道长度方向上，并且如果需要可以集中在盒子或箱子中用于进一步的热固化。
通过这种方法可以连续地制造酚醛泡沫绝热管道型材，且相比常规方法具有少得多的废料和更高的生产率。
示例1
Borden Chemicals公司提供的型号为J60/2325L的苯酚甲醛树脂与16％(pph)的材料141b预混和，材料141b中含有10％的型号为P5050的PFA。它被连续地喂入低压动态混合器中，65％的苯酚磺酸以25pph的速率加入到该混合器中。所产生的预聚物被喂入到连续移动的面层带材上，该面层带材被定形以持有该混合物。混合物整体地以2.5米/分钟的速度被连续地喂入到模具的12米长的双链系统之间，以便外部面层带材如前所述保持为外部模具段形状(直径74毫米)，以与这些模具段相同的速度移动，而内部面层带材在内部加热心棒(直径38毫米)上滑动，该内部心棒沿机器的中心轴线突伸8米。内部心棒被加热到60℃，外部模具段被加热到50℃。
从机器连续地露出来的局部固化的型材被切成适于搬运的适当长度(通常为1米)的段，连续地纵切以允许包在管道长度方向上，并且可以集中到箱子中用于进一步的热固化。如此生产的型材显示了适于用作管道绝热的良好的尺寸稳定性和热传导率。
本发明不限于用于管道或导管的绝热型材。它可以用于，例如，生产具有较高密度的相似形状的短长度段以便用作支撑物等。这种密度通常在50千克/立方米到125千克/立方米的范围内，并且所生产的材料具有足够的抗压强度，以能够支撑可能由本发明的绝热管道型材绝热的管道系统。这种类型的产品就是通常所说的管支架。
本发明并不限于以上所述的可以在细节上变化的实施例。

Claims (40)

1.一种用于连续生产细长酚醛泡沫绝热成形型材的方法，包括以下步骤：
提供第一面层带材；
提供第二面层带材；
将液体酚醛泡沫反应物灌注到所述两面层带材之间；
使面层带材定形，以使得面层带材和泡沫混合物符合预期轮廓形状；
加热内部和外部面层带材；以及
支撑所述面层带材，以将泡沫保持在预期形状，直到泡沫已经固化成成形轮廓型材。
2.如权利要求1所述的方法，其特征在于，内部和外部面层带材被加热到介于45℃到85℃之间的温度。
3.如权利要求1或2所述的方法，其特征在于，内部和外部面层带材都加热到介于50℃到70℃之间的温度。
4.如前述权利要求中任一所述的方法，其特征在于，内部面层带材由心棒定形。
5.如权利要求4所述的方法，其特征在于，所述心棒被加热。
6.如权利要求4或5所述的方法，其特征在于，所述心棒是通过使热交换流体在其中循环而被加热的中空心棒。
7.如权利要求4到6中任一所述的方法，其特征在于，所述心棒至少局部地涂有减摩剂。
8.如权利要求7所述的方法，其特征在于，所述减摩剂为特氟隆。
9.如前述权利要求中任一所述的方法，其特征在于，所述外部面层带材由模具定形。
10.如权利要求9所述的方法，其特征在于，所述模具被加热。
11.如权利要求10所述的方法，其特征在于，所述模具由辐射热加热。
12.如前述权利要求中任一所述的方法，包括后固化细长泡沫绝热成形型材的步骤。
13.如权利要求12所述的方法，其特征在于，所述成形型材在介于20℃到85℃之间的温度下后固化4到48小时。
14.如权利要求12或13所述的方法，其特征在于，所述成形型材在介于50℃到85℃之间的温度下后固化4到48小时。
15.如前述权利要求中任一所述的方法，包括将所述成形型材切割成预期长度。
16.如权利要求15所述的方法，其特征在于，将所述成形型材在线切割成预期长度。
17.如前述权利要求中任一所述的方法，其特征在于，所述细长泡沫绝热成形型材包括中空泡沫体。
18.如权利要求17所述的方法，其特征在于，所述中空体是大体均匀横截面的。
19.如权利要求17或18所述的方法，其特征在于，所述成形型材是曲线形的。
20.如权利要求19所述的方法，其特征在于，所述成形型材是圆筒形的。
21.如权利要求17或18所述的方法，其特征在于，所述成形型材是直线形的。
22.如前述权利要求中任一所述的方法，其特征在于，所述泡沫体包括用于管道的绝热体。
23.如权利要求1到21中任一所述的方法，其特征在于，所述泡沫体包括导管或用于该导管的绝热体。
24.如前述权利要求中任一所述的方法，其特征在于，所述内部面层带材是诸如铝箔的金属箔、纸、玻璃、热塑薄膜或以上两种或多种的组合。
25.如前述权利要求中任一所述的方法，其特征在于，所述外部面层带材是诸如铝箔的金属箔、纸、玻璃、热塑薄膜或以上两种或多种的组合。
26.一种大体上如本申请中所描述的用于连续生产细长泡沫绝热成形型材的方法。
27.一种利用前述权利要求中任一所述的方法生产的细长泡沫绝热成形型材。
28.一种细长成形型材，包括具有大体均匀横截面的中空酚醛泡沫体，该泡沫体具有外部面层带材和内部面层带材。
29.如权利要求28所述的成形型材，其特征在于，所述泡沫体是曲线形的。
30.如权利要求28或29所述的成形型材，其特征在于，所述泡沫体被纵向地切成用于包围一个物体的型材部分。
31.如权利要求30所述的成形型材，其特征在于，所述型材部分在一侧上通过外部面层带材相连。
32.如权利要求31所述的成形型材，其特征在于，所述型材部分的相对端在相反侧上与内部面层带材相面对。
33.如权利要求28到32中任一所述的成形型材，其特征在于，所述泡沫体为大体圆筒形。
34.如权利要求33所述的成形型材，其特征在于，所述泡沫体包括用于管道的绝热体。
35.如权利要求28到32中任一所述的成形型材，其特征在于，所述泡沫体包括导管或用于该导管的绝热体。
36.如权利要求35所述的成形型材，其特征在于，所述泡沫体是直线形的。
37.如权利要求要求28到32中任一所述的成形型材，其特征在于，所述泡沫体包括管支架。
38.如权利要求要求28到37中任一所述的成形型材，其特征在于，所述内部面层带材是诸如铝箔的金属箔、纸、玻璃、热塑薄膜或以上两种或多种的组合。
39.如权利要求要求28到38中任一所述的成形型材，其特征在于，所述外部面层带材是诸如铝箔的金属箔、纸、玻璃、热塑薄膜或以上两种或多种的组合。
40.一种大体上如本申请中所描述的细长成形型材。
CNB2003801057384A 2002-12-12 2003-12-12 绝热泡沫型材及其连续生产方法 Expired - Lifetime CN100453879C (zh)

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