TWI738539B - 發泡產品及其製造方法 - Google Patents

發泡產品及其製造方法 Download PDF

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TWI738539B
TWI738539B TW109136045A TW109136045A TWI738539B TW I738539 B TWI738539 B TW I738539B TW 109136045 A TW109136045 A TW 109136045A TW 109136045 A TW109136045 A TW 109136045A TW I738539 B TWI738539 B TW I738539B
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skin
foamed
foam
top surface
cross
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TW109136045A
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TW202216424A (zh
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葉宗殷
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葉宗殷
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Priority to TW109136045A priority Critical patent/TWI738539B/zh
Priority to US16/953,678 priority patent/US11453198B2/en
Priority to CN202011328993.7A priority patent/CN114379172B/zh
Priority to EP20210004.6A priority patent/EP3984735B1/en
Priority to CA3101581A priority patent/CA3101581C/en
Priority to AU2020286233A priority patent/AU2020286233A1/en
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Publication of TWI738539B publication Critical patent/TWI738539B/zh
Publication of TW202216424A publication Critical patent/TW202216424A/zh

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Abstract

本發明揭露一發泡產品及其製造方法，該發泡產品包括預先製作好的一發泡芯板、一表皮、一有架橋發泡皮及一底板。該有架橋發泡皮先被結合於該發泡芯板的一底面，然後，該表皮再被結合於該發泡芯板的一頂面及一週邊，最後，將該底板結合至該有架橋發泡皮。其中，由於該底板包括一無架橋發泡皮及一非發泡塑膠板，故在該底板結合至該有架橋發泡皮之後，該無架橋發泡皮即被夾在該有架橋發泡皮與該非發泡塑膠板之間。

Description

發泡產品及其製造方法
本發明主要與運動休閒用或救生用的發泡產品有關，尤指該發泡產品的結構與製造方法。
目前，運動休閒用或救生用的發泡產品，例如各種衝浪板、滑雪板、槳板（SUP）、滑草板、滑沙板、救生板、浮板⋯⋯等等，它們基本上都是由一發泡芯板、設置在該發泡芯板頂面的一頂發泡皮、設置在該發泡芯板底面的一底發泡皮、及設置在該底發泡皮底面的一塑膠底板所構成，在US 2019/0184674 A1已例示這類發泡產品的幾種構造，其中一種構造可造成該發泡產品的底面看不到接縫線，只有從該發泡產品的側面才看得到該塑膠底板與該頂發泡皮之間的一道很細的接縫線，這個接縫線其實就是被壓縮得很薄的該底發泡皮的一側邊，理想上，這個接縫線愈細愈好。
本發明提供一種發泡產品，其包括一發泡芯板、一表皮、一有架橋發泡皮、一無架橋發泡皮及一非發泡塑膠板。該發泡芯板具有一頂面、一底面及一週邊。該表皮的一底面覆蓋且結合於該發泡芯板的該頂面。該有架橋發泡皮的一頂面覆蓋且結合於該發泡芯板的該底面。該無架橋發泡皮的一頂面覆蓋且結合於該有架橋發泡皮的一底面。該非發泡塑膠板覆蓋且結合於該無架橋發泡皮的一底面。
在一實施例中，本發明上述表皮還覆蓋到該發泡芯板的該週邊及該有架橋發泡皮的該週邊，但未超出該有架橋發泡皮的該底面，該無架橋發泡皮的該頂面還覆蓋到該表皮的該週邊。
在一實施例中，本發明上述表皮包括一表層發泡皮及一非發泡塑膠膜，該表層發泡皮位於該發泡芯板與該非發泡塑膠膜之間。
在一實施例中，本發明上述表層發泡皮的厚度大於該有架橋發泡皮，該有架橋發泡皮的厚度大於該無架橋發泡皮。
本發明還提供一種發泡產品製造方法，其包括：將預先製作好的一有架橋發泡皮的一頂面覆蓋且結合到預先製作好的一發泡芯板的一底面；將預先製作好的一表皮的一底面覆蓋且結合到該發泡芯板的一頂面；及將預先製作好的一底板結合到該有架橋發泡皮的一底面。其中，該底板包括一無架橋發泡皮及一非發泡塑膠板，該非發泡塑膠板覆蓋且結合到該無架橋發泡皮的一底面，該無架橋發泡皮的一頂面覆蓋且結合到該有架橋發泡皮的該底面。
在一實施例中，本發明上述有架橋發泡皮與上述發泡芯板的結合係按照以下步驟進行：將該有架橋發泡皮放入一發泡成形模具的一模穴內；將已預發泡的顆粒輸入該發泡成形模具的該模穴內；及將高溫蒸氣注入該發泡成形模具，以促使該些已預發泡的顆粒膨脹且相互聚結形成該發泡芯板。
在一實施例中，本發明上述底板係按照下述步驟製成：令一押出機的一輸出口輸出融化成液態的塑膠材料；輸送該無架橋發泡皮經過該押出機的該輸出口，以使該塑膠材料淋覆於該無架橋發泡皮的該底面；及對該無架橋發泡皮及已淋覆在該無架橋發泡皮上的該塑膠材料進行一滾壓作業。
相對於先前技術，依本發明上述方法所製成的上述發泡產品，共有上述有架橋發泡皮與無架橋發泡皮等兩層材料被夾在上述發泡芯板與非發泡塑膠板之間，這是相關發泡產品過去所未見的結構。
圖1至圖5顯示一種發泡產品，在此實施例中該發泡產品係為一衝浪板，然而，該發泡產品也可以是一槳板（SUP）、一滑雪板、、一滑草板、一滑沙板、一救生板、一浮板、一浮標或是其它發泡產品。
如圖1至圖3所示，該發泡產品包括一發泡芯板1、一表皮2、一有架橋發泡皮31及一底板32。底板32包括一無架橋發泡皮321及一非發泡塑膠板322。較佳地，有架橋發泡皮31的發泡倍率大於無架橋發泡皮321。
發泡芯板1由塑膠發泡材料製成。該塑膠發泡材料可選擇發泡聚苯乙烯（EPS）、發泡聚乙烯（EPE）、發泡聚丙烯（EPP）、或發泡苯乙烯-乙烯混合體（以聚苯乙烯及聚乙烯共聚而成，並經架橋處理發泡而成），但不以此為限。
表皮2可以是一層發泡皮，也可以是包含至少一層發泡皮的多層複合皮料。在此實施例中，如圖3所示，表皮2包括一表層發泡皮21及一非發泡塑膠膜22。非發泡塑膠膜22覆蓋且結合於表層發泡皮21的一頂面210。表層發泡皮21可以是一聚乙烯發泡皮或聚丙烯發泡皮，它的發泡倍率較佳是15（換算後約為64 kg/m3或4 PCF），厚度大約2~6mm，較佳是4mm。非發泡塑膠膜22較佳是由聚乙烯製成，厚度大約是0.05~0.1mm。在此實施例中，非發泡塑膠膜22還具有一印刷圖案220。
有架橋發泡皮31是一種已經摻入化學架橋劑或已經經過電子架橋處理的聚乙烯發泡皮、聚丙烯發泡皮或其它發泡皮，它的發泡倍率較佳是30（換算後即33 kg/m3或2.1 PCF），厚度較佳是大約2mm。無架橋發泡皮321則是一種沒有摻入化學架橋劑也沒有經過電子架橋處理的聚乙烯發泡皮、聚丙烯發泡皮或其它發泡皮，它的發泡倍率較佳是20（換算後約為48 kg/m3或 3 PCF）。無架橋發泡皮321原始厚度較佳是大約2mm，但這個厚度會隨著它被壓縮的程度而變小（此容後再述）。有架橋發泡皮31的質地比無架橋發泡皮321硬，比較不容易被壓縮變薄。相反的，相對於有架橋發泡皮31，無架橋發泡皮321的質地較軟，也比較容易被壓縮變薄。
從上述說明可知，在發泡倍率上的安排，有架橋發泡皮31的發泡倍率大於無架橋發泡皮321，無架橋發泡皮321的發泡倍率則大於表層發泡皮21。在厚度上的安排，表層發泡皮21的厚度大於有架橋發泡皮31，有架橋發泡皮31的厚度大於無架橋發泡皮321。
再如圖1至圖3所示，發泡芯板1具有一頂面10、一底面11、及介於頂面10與底面11之間的一週邊12。表皮2具有一頂面200、一底面201、及介於頂面200與底面201之間的一週邊202。其中，表皮2的底面201（即上述表層發泡皮21的一底面211）是覆蓋且結合於發泡芯板1的頂面10。
有架橋發泡皮31具有一頂面311、一底面312及介於頂面311與底面312之間的一週邊313。無架橋發泡皮321具有一頂面321a及一底面321b。有架橋發泡皮31的頂面311覆蓋且結合於發泡芯板1的底面11，無架橋發泡皮321的頂面321a覆蓋且結合於有架橋發泡皮31的底面312 。至於非發泡塑膠板322則覆蓋且結合於無架橋發泡皮321的底面321b。
在此實施例中，表皮2還覆蓋到發泡芯板1的週邊12及有架橋發泡皮31的週邊313，但未超出有架橋發泡皮31的底面312，無架橋發泡皮321的頂面321a還覆蓋到表皮2的週邊202。因此，如圖4所示，從該發泡產品的底部看過去，只會看到非發泡塑膠板322，但看不到任何接縫線。
圖6顯示本發明上述發泡產品的製造方法的一個較佳實施例，該製造方法包括步驟a至c，茲說明如下：
首先，如步驟a所示，將有架橋發泡皮31的頂面311覆蓋且結合到發泡芯板1的底面11；
其次，如步驟b所示，將表皮2的底面201覆蓋且結合到發泡芯板1的頂面10 ；以及
如步驟c所示，將底板32結合到有架橋發泡皮31的底面312。其中，底板32的無架橋發泡皮321的頂面321a係覆蓋且結合到有架橋發泡皮31的底面312。
在步驟a中，發泡芯板1可先預先製作完成，然後再以熱壓結合方式將有架橋發泡皮31結合至發泡芯板1的底面11，或者，也可改採其它方式達到將有架橋發泡皮31結合至發泡芯板1的目的，例如：先將有架橋發泡皮31放入一發泡成形模具（圖中未示）的一模穴內，然後，將已預發泡的顆粒（例如已預發泡的聚苯乙烯顆粒）輸入該發泡成形模具的該模穴內，接著，將高溫蒸氣注入該發泡成形模具，以促使該些已預發泡的顆粒膨脹且相互聚結形成發泡芯板1（例如聚苯乙烯發泡芯板）。藉由前述步驟，不但可製作出發泡芯板1，還可一併將有架橋發泡皮31結合到發泡芯板1的底面11。
在步驟b中，表皮2是事先製作完成的，較佳是選用熱壓結合方式將表皮2結合到發泡芯板1的頂面10。其中，表皮2的面積可以大致相當於發泡芯板1的頂面10，以使表皮2僅覆蓋且結合於頂面10，然而，表皮2的面積也可以大致相當於發泡芯板1的頂面10及週邊12，以使表皮2不但覆蓋且結合於頂面10，還進一步覆蓋且結合至週邊12。
在步驟c中提到的底板32是事先製作好的。如圖7所示，一押出機4的一輸出口41連續輸出融化成液態的塑膠材料30（例如液態的聚乙烯材料），而事先製作好的無架橋發泡皮321（例如無架橋的聚乙烯發泡皮）被連續輸送經過押出機4的輸出口41，以使塑膠材料30淋覆於無架橋發泡皮321的底面321b。接著，使用一對滾輪5對無架橋發泡皮321及已淋覆在無架橋發泡皮321上的塑膠材料30進行一滾壓作業，至此，即完成底板32的製作。
需指出的是，剛從押出機4的輸出口41輸出的塑膠材料30的溫度大約是在220～240 °C，這樣的高溫已足以使無架橋發泡皮321的底面321b與塑膠材料30發生融合。在融合的過程，無架橋發泡皮321的底面321b在深度方向會被融化掉一小部分，該被融化掉部分會被融入塑膠材料30而一起形成底板32的非發泡塑膠板322，使得非發泡塑膠板322變厚，與此同時，底板32的無架橋發泡皮321也會因為已被融化掉該小部分而相對變薄。依前方式形成的非發泡塑膠板322的厚度約為0.8mm，但不以此為限。無論如何，非發泡塑膠板322應具有質地堅韌且耐磨的特點，並應具有一光滑底面以供滑行於一滑行表面（例如水面）。
此外，在步驟c中，已依圖7所示方式預先製作好的底板32是採用熱壓方式結合到有架橋發泡皮31。由於底板32上的無架橋發泡皮321很容易被壓縮，故在完成將底板32結合到有架橋發泡皮31的作業之後，在此作業中受到重壓的無架橋發泡皮321將進一步變薄，例如大約0.1～0.5mm。因此，如圖1及圖5所示，從該發泡產品的側邊看過去，只會看非發泡塑膠板322與表皮2之間有一條很細的接縫線324，這個接縫線324其實就是變薄後的無架橋發泡皮321的一側邊，，因此，人們只會注意到該發泡產品的非發泡塑膠板322與表皮2，幾乎察覺不到無架橋發泡皮321的存在，也當然看不到有架橋發泡皮31，因為它已經被表皮2包覆了。
1:發泡芯板
10:頂面
11:底面
12:週邊
2:表皮
200:頂面
201:底面
202:週邊
21:表層發泡皮
210:頂面
22:非發泡塑膠膜
220:印刷圖案
31:有架橋發泡皮
30:塑膠材料
311:頂面
312:底面
313:週邊
32:底板
321:無架橋發泡皮
322:非發泡塑膠板
321a:頂面
321b:底面
a~c:步驟
4:押出機
41:輸出口
5:對滾輪
圖1為本發明之發泡產品的一個較佳實施例的前段部分的立體圖。 圖2為該較佳實施例的橫斷面結構示意圖。 圖3為圖2的部分放大圖。 圖4為本發明該發泡產品的仰視示意圖。 圖5為本發明該發泡產品的部分側視示意圖。 圖6顯示本發明之發泡產品製造方法的一個較佳實施例的流程圖。 圖7顯示本發明之底板32的製作示意圖。
1:發泡芯板
10:頂面
11:底面
12:週邊
2:表皮
200:頂面
201:底面
202:週邊
31:有架橋發泡皮
311:頂面
312:底面
313:週邊
32:底板
321:無架橋發泡皮
322:非發泡塑膠板

Claims (6)

  1. 一種發泡產品，包括：一發泡芯板，具有一頂面、一底面及一週邊；一表皮，具有一頂面、一底面及一週邊，其中，該表皮的該底面覆蓋且結合於該發泡芯板的該頂面；一有架橋發泡皮，具有一頂面、一底面及一週邊，其中，該有架橋發泡皮的該頂面覆蓋且結合於該發泡芯板的該底面；一無架橋發泡皮，具有一頂面及一底面，其中，該無架橋發泡皮的該頂面覆蓋且結合於該有架橋發泡皮的該底面；及一非發泡塑膠板，覆蓋且結合於該無架橋發泡皮的該底面；其中，該表皮還覆蓋到該發泡芯板的該週邊及該有架橋發泡皮的該週邊，但未超出該有架橋發泡皮的該底面，該無架橋發泡皮的該頂面還覆蓋到該表皮的該週邊。
  2. 如請求項1所述的發泡產品，其中，該表皮包括一表層發泡皮及一非發泡塑膠膜，該表層發泡皮位於該發泡芯板與該非發泡塑膠膜之間。
  3. 如請求項2所述的發泡產品，其中，該表層發泡皮的厚度大於該有架橋發泡皮，該有架橋發泡皮的厚度大於該無架橋發泡皮。
  4. 一種發泡產品製造方法，包括：將預先製作好的一有架橋發泡皮的一頂面覆蓋且結合到預先製作好的一發泡芯板的一底面；將預先製作好的一表皮的一底面覆蓋且結合到該發泡芯板的一頂面；及將預先製作好的一底板以熱壓方式結合到該有架橋發泡皮的一底面，其中，該底板包括一無架橋發泡皮及一非發泡塑膠板，該非發泡塑膠板覆蓋且結合到該無架橋發泡皮的一底面，該無架橋發泡皮的一頂面覆蓋且結合到該有架橋發泡皮的該底面。
  5. 如請求項4所述的發泡產品製造方法，其中該有架橋發泡皮與該發泡芯板的結合係按照以下步驟進行：將該有架橋發泡皮放入一發泡成形模具的一模穴內；將已預發泡的顆粒輸入該發泡成形模具的該模穴內；及將高溫蒸氣注入該發泡成形模具，以促使該些已預發泡的顆粒膨脹且相互聚結形成該發泡芯板。
  6. 如請求項4或5所述的發泡產品製造方法，其中該底板係按照下述步驟製成：令一押出機的一輸出口輸出融化成液態的塑膠材料；輸送該無架橋發泡皮經過該押出機的該輸出口，以使該塑膠材料淋覆於該無架橋發泡皮的該底面；及對該無架橋發泡皮及已淋覆在該無架橋發泡皮上的該塑膠材料進行一滾壓作業。
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CN202011328993.7A CN114379172B (zh) 2020-10-16 2020-11-24 发泡产品及其制造方法
EP20210004.6A EP3984735B1 (en) 2020-10-16 2020-11-26 Foam product and manufacturing method thereof
CA3101581A CA3101581C (en) 2020-10-16 2020-12-03 Foam product and manufacturing method thereof
AU2020286233A AU2020286233A1 (en) 2020-10-16 2020-12-09 Foam product and manufacturing method thereof

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TW201307060A (zh) * 2011-08-10 2013-02-16 Tzong-In Yeh 多層板及其製法與發泡產品
US20130038041A1 (en) * 2011-08-11 2013-02-14 Atomic Austria Gmbh Ski or snowboard and method for the production thereof
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TW201927382A (zh) * 2017-12-14 2019-07-16 葉宗殷 滑板結構

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CA3101581C (en) 2022-06-21
CA3101581A1 (en) 2021-12-20
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US20220118661A1 (en) 2022-04-21
EP3984735A1 (en) 2022-04-20

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