DE4240285A1 - Surfacing foam with e.g. scourer layer - by coating moving substrate with fused resin powder from heated roller and bonding prod. to web of surfacing material with pressure roller - Google Patents

Abstract

A surfacing device utilises a fusible resin powder on the back of a foam substrate of 5-80 kg/m3 polyether, polyester, "Pantex" or a viscose resin/mat slab material etc. The coating bonds a harder material e.g. a scouring mat, a massaging surface, cleaning surface, etc. onto it. The fusible powder is fed from a hopper onto a revolving heated roller and the substrate is passed to that roller on a conveyor belt. A melted film is rolled onto the substrate and the harder skin material is bonded onto it by a second roller. Resin powder (6) is deposited from the hopper (1) onto the roller (2) below, using e.g. a screw feed or a vibrator. The roller (2) is driven and (e.g.) doctored. It is heated e.g. by a silicone oil agent or by a radiation heater, so that the deposited resin powder (6) forms a liquid film (7) which is applied to the substrate (8) passing underneath. The speed of rotation of the roller (2) is selected to produce a resin film of the desired thickness (7). The substrate (8) lies on the belt (4). An infra-red heater (5) can further fuse the resin coating before the material plus an added skin (9) (e.g. scouring mat) are bonded together by the next roller (3). The product (10) is finally cut to size as required. ADVANTAGE - The arrangement can cheaply surface sheets or webs of any width.

Description

The present invention relates to a device for lamination, in particular a sponge or household sponge, using hot-meltable plastic powder on the underside of a foam carrier material made of polyether, polyester or pantex with a density of 50 to 80 kg per m ³ or of viscose - Sponge material made of blocked plastic fiber fleece or the like, a harder part element, such as a scouring fleece, a massage surface, a cleaning body or the like, is laminated on.

Under the term "pot sponge" is a combination sponge body understood that consists of at least one foam carrier material, a scrubbing fleece is laminated on the underside.

The term "household sponge" is understood to mean a sponge body which is preferably made of a polyurethane or a Polyether sponge material is made on the underside of another Body is laminated. The other body as a harder sub-element can be a massage surface, a fly sponge body with or without Abrasive or a sponge body with a plaster surface is combined.

With all the sponges mentioned above, it is essential that a Inexpensive, simple - yet durable - connection between  the carrier material - here the foam body - and the one underneath lying harder part of the cleaning or cleaning body will be produced.

For the sake of simplicity, only the Connection of a foam carrier material with a harder one Sub-element consisting of a scouring fleece described.

However, this should not be understood as restrictive, since in the frame all possible and known combinations of the present invention between a foam backing and an attached to it Laminated or adhesive connection to be attached to harder part fall, especially a scrub, cleaning or massage fleece.

The replacement of the also falls within the scope of the present invention Backing material consisting of a foam body through a other body, e.g. B. a viscose sponge, which is based on the following descriptive lamination with a harder one underneath Partial element, such as a scouring, cleaning or massage body, is connected.

A device for lamination of the type mentioned is already known, the hot melt powder directly on the carrier material is applied and liquefied by means of infrared radiators. That loose Sprinkling the powder is relatively inaccurate, so that the Laminating the harder part element could form bumps.

It is also known to flame the foam backing material, in the liquefied surface layer then the harder Sub-element was laminated. However, this leads to a Environmental pollution when the foam backing material is flamed and in further, only very specific carrier materials that the Liquefaction accessible.

It is also known that the harder part element with a  Two-component PU adhesive with the foam carrier material too connect. Here, however, there is the disadvantage that a health hazard when using the adhesive and when Curing of the adhesive is to be feared.

It is also known to add a hot-melt film to the lamination use an adhesive bond between the To achieve carrier material and the harder sub-element. Here is However, the disadvantage is based on the fact that the hot melt film is relatively involves high price and the need continues to exist The size of the hot-melt film is exactly that of the web material to be glued adapt.

The present invention is therefore based on the object Device for lamination, in particular a pot or Household sponge to develop so that web or plate goods any width in a reliable manner and in a cost-effective manner can be connected to each other.

To achieve the object, the invention provides the features of characterizing part of protection claim 1.

The essence of the invention lies in the fact that starting from one heated a liquefied plastic film on the roller Foam backing material is laminated on top of it the liquid adhesive layer provided carrier material in one subsequent lamination process, the harder sub-element, in particular a Abrasive fleece or the like, is laminated.

With the given technical teaching, the main advantage achieved that a very precise dosage on the heated roller thin liquid plastic film on the foam carrier material is applied, the thickness of the plastic film or Adhesive layer is adapted exactly to the requirements. In this way  an adhesive layer is defined on the foam carrier material Thickness applied in a thin arrangement, so that later Laminating process with the harder sub-element no hardening or Bumps or the like may result in inaccurate bonds.

The hot melt powder is preferably a powder which is made of polyester, polyamide, polyethylene or EVA plastic consists.

In a preferred embodiment it is provided that the bulk hopper has a forced distribution for the plastic powder.

In connection with the forced distribution, the is advantageous Bulk funnel designed as a vibration funnel or the Schütt funnel has screw conveyors or at the outlet end of the Schütt-Funnel is a rotating roller with circular grooves arranged, one wiping lip and opposite one Bristle roller are provided.

By using the hopper with a forced distribution a very precise dosage and fine distribution of the bulk material or Plastic powder reached on the heated roller, so that a liquefied plastic film of defined size with always repeatable Application can be applied to the carrier material.

In a further embodiment, it is advantageous that the heated roller an infrared radiator is connected in front of the laminating gap is arranged.

The arrangement of an additional infrared radiator is required selected, with further liquefaction of the plastic film the carrier material is reached before this material in the Laminating roll nip is initiated.  

The subject matter of the present invention does not arise only from the subject of the individual protection claims, but also from the combination of the individual protection claims.

All in the documentation - including the summary - Disclosed information and features, especially those in the drawings Spatial training shown are bean essential to the invention speaks, insofar as they are individually or in combination with the state of the Technology are new.

In the following the invention is based on only one Execution path illustrating drawing explained in more detail. Go here from the drawing and their description further fiction essential features and advantages of the invention.

From the drawing, the device shows the heated roller 2 on which the bulk material - here hot-melt powder 6 - is scattered out of a bulk hopper 1 .

The heated roller 2 is PTFE-coated and filled with heat transfer fluid.

In one embodiment, it is possible that the hopper 1 is designed accordingly to achieve a fine distribution of the plastic powder 6 on the roller 2 . For this purpose, screw conveyors can be provided or the hopper 1 is designed as a vibration hopper or a rotating roller is provided at the outlet end of the hopper 1 , circular rollers being present in the roller, which take a mutual distance from one another and furthermore rotate the roller is driven.

By this rotary drive of the roller, the plastic powder 6 is partly taken up in grooves and conveyed downwards out of the hopper 1 , a wiping lip being present which only lets out the part of the powder which has accumulated in the grooves. A bristle roller is then arranged on the opposite side of the discharge area of the hopper 1 , which strips and cleans the grooves, which may then be partially filled, so that the grooves are turned back empty in the hopper 1 and are free to receive new ones Powder 6 are.

The heated roller 2 is heated with a heat transfer fluid, e.g. B. with silicone oil, water or the like.

It is also possible to heat the roller 2 in a different way, e.g. B. with an internal heater or the like.

The heat-fusible powder 6 is sprinkled on the heated roller 2 via the bulk hopper 1 as bulk material, and then a liquefied plastic film 7 is formed on the roller 2 , which, when the roller 2 rotates counterclockwise, onto the carrier material 8 , here a sponge material is applied.

The speed of rotation of the roller 2 is selected so that it is ensured that a liquefied plastic film 7 forms on the area of the roller 2 and that loose powder 6 does not fall onto the underlying substrate 8 .

Furthermore, the speed of rotation is selected so that a plastic film 7 of a certain defined thickness is formed, this plastic film 7 not being too thin.

In the illustration shown, the sponge or carrier material 8 lies on a conveyor belt 4 and is transported in the direction of the arrow shown.

After the plastic film 7 has been rolled onto the carrier material 8 , an infrared radiator 5 can also be provided, which further liquefies the plastic film on the carrier material 8 before this material is introduced into the laminating roll nip.

The Kaschierwalzenspalt is formed in the embodiment by a deflecting roll 3, wherein on the guide roller 3 the harder part element 9, here a scouring non-woven, is supplied, and provided in the other of the liquefied with the plastic film 7 support material is laminated. 8

The finished lamination 10 then forms at the exit of the device, which is then subsequently cut into blocks or handy pieces.

Drawing legend

1 funnel funnel Forced distribution
2 Heated roller. PTFE coated, filled with heat transfer fluid
3 deflection roller for fleece
4 conveyor belt
5 infrared heaters
6 bulk plastic powder
7 liquefied plastic film
8 sponge (carrier material)
9 abrasive fleece (harder part element)
10 finished lamination

Claims (4)

1. Device for lamination, in particular a pot or household sponge, using hot-meltable plastic powder on the underside of a foam carrier material made of polyether, polyester or pantex with a density of 5 to 80 kg per m ³ or of viscose sponge material made of blocked plastic Fiber fleece or the like, a harder sub-element, such as a scrubbing fleece, a massage surface, a cleaning body or the like, is laminated on, characterized in that hot-meltable plastic powder ( 6 ) is fed via a hopper ( 1 ) to a heated, rotating roller ( 2 ) and that the carrier material ( 8 ) is fed via a conveyor belt ( 4 ) to the roller ( 2 ), a liquefied plastic film ( 7 ) being rolled onto the carrier material ( 8 ) and that the roller ( 2 ) has a deflection roller ( 3 ) is connected downstream, where the harder sub-element ( 9 ) is laminated onto the carrier material in a laminating gap. 2. Device according to claim 1, characterized in that the bulk hopper ( 1 ) has a forced distribution for the plastic powder ( 6 ). 3. Device according to claims 1 and 2, characterized in that the bulk hopper ( 1 ) is designed as a vibratory hopper or has screw conveyors or at the outlet end of the bulk hopper ( 1 ) a rotating roller with circular grooves is arranged, a wiping lip and a bristle roller is provided opposite. 4. The device according to claim 1, characterized in that the heated roller ( 2 ) is followed by an infrared radiator ( 5 ) which is arranged in front of the laminating gap.