GB2137933A - Method of manufacturing laminated plastics materials - Google Patents

Method of manufacturing laminated plastics materials Download PDF

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Publication number
GB2137933A
GB2137933A GB08406970A GB8406970A GB2137933A GB 2137933 A GB2137933 A GB 2137933A GB 08406970 A GB08406970 A GB 08406970A GB 8406970 A GB8406970 A GB 8406970A GB 2137933 A GB2137933 A GB 2137933A
Authority
GB
United Kingdom
Prior art keywords
sheet
barrier
foam
passage
sheet material
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
GB08406970A
Other versions
GB2137933B (en
GB8406970D0 (en
Inventor
William David Brewer
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Individual
Original Assignee
Individual
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from GB838309033A external-priority patent/GB8309033D0/en
Application filed by Individual filed Critical Individual
Publication of GB8406970D0 publication Critical patent/GB8406970D0/en
Publication of GB2137933A publication Critical patent/GB2137933A/en
Application granted granted Critical
Publication of GB2137933B publication Critical patent/GB2137933B/en
Expired legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—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
    • 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
    • B32B5/20—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 foamed in situ
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • 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
    • B29C44/1228—Joining preformed parts by the expanding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • 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
    • B29C44/20—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
    • B29C44/30—Expanding the moulding material between endless belts or rollers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • 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
    • B29C44/20—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
    • B29C44/32—Incorporating or moulding on preformed parts, e.g. linings, inserts or reinforcements
    • B29C44/326—Joining the preformed parts, e.g. to make flat or profiled sandwich laminates
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • 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
    • B29C44/34—Auxiliary operations
    • B29C44/36—Feeding the material to be shaped
    • B29C44/46—Feeding the material to be shaped into an open space or onto moving surfaces, i.e. to make articles of indefinite length
    • B29C44/467—Foam spreading or levelling devices
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/18—Handling of layers or the laminate
    • B32B38/1808—Handling of layers or the laminate characterised by the laying up of the layers
    • B32B38/1816—Cross feeding of one or more of the layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—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
    • B32B5/22—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 the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/30—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 the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being formed of particles, e.g. chips, granules, powder
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B32B2266/0214—Materials belonging to B32B27/00
    • B32B2266/0278—Polyurethane

Description

SPECIFICATION Method of Manufacturing Laminated Plastics Materials This invention relates to a method of manufacturing laminated plastics materials, particularly to a method of manufacturing materials comprising a layer of foamed plastics material such as polyurethane laminated between sheets of one or more other materials in a continuous process.
Such laminated materials have been manufactured by processes in which a liquid, unfoamed prepolymer is sprayed onto the surface of a first sheet of material, allowed to foam and before foaming is complete, a second sheet of material is applied upon the foaming mixture. The sheets are then passed through a press to create an even thickness of foamed mixture between the sheets.
Alternatively, individual stream of prepolymer reagents have been applied to the first sheet and the foaming mixture passed through spaced rollers together with the second sheet.
Both of these methods suffer from the disadvantage-that uneven distribution of the foam occurs between the sheets, making it necessary to post treat the laminate by rolling or pressing.
Conventional apparatus is difficult to adjust since the apparatus is complex and there are many variable parameters.
According to the present invention a method of manufacturing laminated material comprises the steps of passing a first sheet material adjacent a barrier in spaced relation to the latter and disposed obliquely to the direction of passage and applying a quantity of unfoamed prepolymer at or adjacent to the edge of the first sheet upstream of the most upstream part of the barrier.
The oblique barrier serves to spread the foam across the first sheet as the latter passes under the barrier. The first sheet may be supported on a lower support such as a conveyor or fixed bed.
The barrier is preferably parallel to the first sheet so that an even thickness of foam mixture is applied to the sheet A non-parallel barrier may be employed to compensate for compression of the foaming material and consequent non-parallel expansion after passage under the barrier. The barrier may be straight or curved in the plane of the first sheet material. The separation between the first sheet material and the barrier is preferably less than the thickness of the foamed layer of the laminate. Polyurethane foams may have an expansion ratio of 35: 1. A separation of 0.3 mm may be employed to provide a thickness of foam of 1 cm.
The quantity of unfoamed prepolymer may be applied to the first sheet at two or more locations.
In preferred embodiments of the invention a second sheet material is applied upon the foaming polymer. The resultant laminate may have the form of a layer of foamed material sandwiched between two layers of sheet material.
The second sheet material may be applied by passage of the first sheet and foam under a barrier under which the second sheet is also passed. The barrier serves to ensure even distribution of the foam.
Alternatively and more preferably the barrier may comprise a straight linear bar, roller, rod or like elongate structure arranged at between 30 to 60 , preferably 45 to the direction of passage of the first sheet. A slightly non-liner barrier may be alternatively used, non-linearity of the foamed product being compensated by subsequent rolling or other processing. A second sheet may be fed around the barrier and applied directly to the foaming mixture as the latter passes under the barrier. The laminate may be subsequently passed through one or more rollers or presses to ensure even distribution of the foam.
This invention relates particularly to laminates comprising foamed polyurethane although any other convenient foamed polymers may be used.
The apparatus for carrying out the method is preferably disposed in a generally horizontal plane. Alternatively, the first sheet may pass vertically adjacent the barrier.
The laminate containing the foamed polymer may be heated to cure the foam if necessary.
The invention will now be described by means of example and not in any limitative sense with reference to the accompanying drawing, which shows apparatus for performance of the method in accordance with this invention.
The first sheet 1 of flexible paper, plastics or metal sheeting or of a rigid material such as plastics, wood or metal is passed by a conveyor, live rollers or other means under a bar 4, the latter being arranged at 45 to the direction of passage of the sheet 1. Alternatively, the sheet 1 may be drawn through the apparatus by a take up roller or conveyor. The bar 4 in some embodiments of the invention may be curved in the plane of the drawings. However, a straight bar is preferred.
The bar may also take the form of a rotatable roller under which the second sheet 2 is passed. A non-rotatable bar 4 may be preferred to minimise lateral creep of the sheet 2. The separation between the sheet 1 and bar 4 is preferably constant across the width of the sheet.
Alternatively the centre of the bar may be curved towards the first sheet to compensate for uneven, non-parallel expansion of the foam which may otherwise lead to the sheet being thicker at the centre. than at the edges. The second sheet 2 may be composed of paper, plastics metal foil, metallised plastics or any other flexible material.
Mixed polyurethane prepolymer is placed continuously upon the sheet at 3. The separation of the bar 4 is arranged so that the separation between the sheets 1 and 2, for example 0.5 mm, is sufficient to produce a foamed layer of a required thickness, for example 23 mm, after passage under the bar and subsequent expansion and solidification of the foam. The motion of the sheets under the bar 4 causes the foam mixture to be evenly distributed across their width as shown by the arrow 7. A roller 5, which is optional, serves to smooth the laminate.
The bar 4 may be arranged at any convenient angle although angles between 30 and 60 and particularly 45 are preferred.
Use of this method has the advantage that there are no fumes produced as is the case when using a spray to distribute the prepolymer. Better distribution is achieved than when using individual streams of prepolymer applied to the sheets. The simplicity of the apparatus makes it easy to control the thickness and uniformity of the product without expensive trial running of the apparatus. The rate of passage of the sheets through the apparatus is greater than when using conventional methods, speeds of 30 m/minute or greater being attainable. This may be important when using fast curing polyurethane foams.

Claims (11)

1. A method of manufacturing laminated material comprising the steps of passing a first sheet material adjacent a barrier in spaced relation to the latter the barrier being disposed obliquely to the direction of passage, applying a quantity of unfoamed prepolymer at or adjacent to the edge of the first sheet upstream of the most upstream part of the barrier and allowing the polymer to foam as it passes adjacent the barrier.
2. A method as claimed in claim 1, wherein the barrier is parallel to the first sheet.
3. A method as claimed in claim 1 or 2, wherein a second sheet material is applied upon the foaming layer.
4. A method as claimed in claim 3, wherein the second sheet material is applied by passage of the first sheet material and foam adjacent the barrier together with the second sheet material.
5. A method as claimed in any preceding claim, wherein the barrier is selected from a bar, roller, rod or other elongate structure arranged at an angle of 30 to 60 to the direction of passage of the first sheet.
6. A method as claimed in claim 5, wherein the angle is 45 .
7. A method as claimed in any preceding claim, wherein the laminated material is passed through one or more rollers.
8. A method as claimed in any preceding claim, wherein the polymer is polyurethane.
9. A method as claimed in any preceding claim, wherein the sheet materials are flexible and are selected from paper or plastics materials, metal foil or metallised plastics materials.
10. A method substantially as hereinbefore described with reference to the accompanying drawing.
11. A laminated material manufactured in accordance with any preceding claim.
GB08406970A 1983-03-31 1984-03-16 Method of manufacturing laminated plastics materials Expired GB2137933B (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB838309033A GB8309033D0 (en) 1983-03-31 1983-03-31 Manufacturing laminated plastics materials
EP83303500A EP0121017B1 (en) 1983-03-31 1983-06-16 Method of manufacturing laminated plastics material

Publications (3)

Publication Number Publication Date
GB8406970D0 GB8406970D0 (en) 1984-04-18
GB2137933A true GB2137933A (en) 1984-10-17
GB2137933B GB2137933B (en) 1986-10-01

Family

ID=26089274

Family Applications (1)

Application Number Title Priority Date Filing Date
GB08406970A Expired GB2137933B (en) 1983-03-31 1984-03-16 Method of manufacturing laminated plastics materials

Country Status (2)

Country Link
AT (1) ATE30130T1 (en)
GB (1) GB2137933B (en)

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB781475A (en) * 1954-07-28 1957-08-21 B B Chem Co Ltd Improvements in or relating to adhesive spreading tools
GB1326910A (en) * 1969-11-12 1973-08-15 Eastman Kodak Co Method and apparatus for developing a latent electrostatic image
GB1327642A (en) * 1970-08-27 1973-08-22 Neumuenster Masch App Apparatus for applying liquids to films
GB2104616A (en) * 1981-08-10 1983-03-09 Raychem Corp Method of wrapping tape around a pipe

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB781475A (en) * 1954-07-28 1957-08-21 B B Chem Co Ltd Improvements in or relating to adhesive spreading tools
GB1326910A (en) * 1969-11-12 1973-08-15 Eastman Kodak Co Method and apparatus for developing a latent electrostatic image
GB1327642A (en) * 1970-08-27 1973-08-22 Neumuenster Masch App Apparatus for applying liquids to films
GB2104616A (en) * 1981-08-10 1983-03-09 Raychem Corp Method of wrapping tape around a pipe

Also Published As

Publication number Publication date
GB2137933B (en) 1986-10-01
ATE30130T1 (en) 1987-10-15
GB8406970D0 (en) 1984-04-18

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Legal Events

Date Code Title Description
PCNP Patent ceased through non-payment of renewal fee

Effective date: 19930316