WO2017077332A1 - Procédé de formation d'objets polymères moussés - Google Patents
Procédé de formation d'objets polymères moussés Download PDFInfo
- Publication number
- WO2017077332A1 WO2017077332A1 PCT/GB2016/053458 GB2016053458W WO2017077332A1 WO 2017077332 A1 WO2017077332 A1 WO 2017077332A1 GB 2016053458 W GB2016053458 W GB 2016053458W WO 2017077332 A1 WO2017077332 A1 WO 2017077332A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- layer
- mold
- polymeric material
- charge
- polymer
- Prior art date
Links
- 238000000034 method Methods 0.000 title claims abstract description 105
- 239000000463 material Substances 0.000 claims abstract description 117
- 238000005187 foaming Methods 0.000 claims abstract description 19
- 239000002666 chemical blowing agent Substances 0.000 claims abstract description 11
- 229920000642 polymer Polymers 0.000 claims description 18
- 239000004814 polyurethane Substances 0.000 claims description 18
- 239000004753 textile Substances 0.000 claims description 18
- 229920002635 polyurethane Polymers 0.000 claims description 17
- 239000000853 adhesive Substances 0.000 claims description 13
- 230000001070 adhesive effect Effects 0.000 claims description 12
- 229920002334 Spandex Polymers 0.000 claims description 8
- 230000001681 protective effect Effects 0.000 claims description 8
- 229920000126 latex Polymers 0.000 claims description 6
- 229920001200 poly(ethylene-vinyl acetate) Polymers 0.000 claims description 6
- 229920000728 polyester Polymers 0.000 claims description 6
- 229920000573 polyethylene Polymers 0.000 claims description 6
- -1 polyethylenes Polymers 0.000 claims description 6
- 229920000098 polyolefin Polymers 0.000 claims description 6
- 229920003051 synthetic elastomer Polymers 0.000 claims description 6
- 229920002725 thermoplastic elastomer Polymers 0.000 claims description 6
- 238000003892 spreading Methods 0.000 claims description 5
- 230000007480 spreading Effects 0.000 claims description 5
- 229920001468 Cordura Polymers 0.000 claims description 4
- 229920000742 Cotton Polymers 0.000 claims description 4
- 239000004952 Polyamide Substances 0.000 claims description 4
- 239000004698 Polyethylene Substances 0.000 claims description 4
- 239000004793 Polystyrene Substances 0.000 claims description 4
- 229920003235 aromatic polyamide Polymers 0.000 claims description 4
- 239000012237 artificial material Substances 0.000 claims description 4
- 239000002184 metal Substances 0.000 claims description 4
- 239000000203 mixture Substances 0.000 claims description 4
- 239000004745 nonwoven fabric Substances 0.000 claims description 4
- 229920001778 nylon Polymers 0.000 claims description 4
- 229920003023 plastic Polymers 0.000 claims description 4
- 239000004033 plastic Substances 0.000 claims description 4
- 229920002647 polyamide Polymers 0.000 claims description 4
- 229920001296 polysiloxane Polymers 0.000 claims description 4
- 229920002223 polystyrene Polymers 0.000 claims description 4
- 229920001343 polytetrafluoroethylene Polymers 0.000 claims description 4
- 229920000915 polyvinyl chloride Polymers 0.000 claims description 4
- 239000004800 polyvinyl chloride Substances 0.000 claims description 4
- 239000004759 spandex Substances 0.000 claims description 4
- 239000005061 synthetic rubber Substances 0.000 claims description 4
- 125000000391 vinyl group Chemical group [H]C([*])=C([H])[H] 0.000 claims description 4
- 229920002554 vinyl polymer Polymers 0.000 claims description 4
- 239000002759 woven fabric Substances 0.000 claims description 4
- 230000001747 exhibiting effect Effects 0.000 claims description 3
- 229920002943 EPDM rubber Polymers 0.000 claims description 2
- VGGSQFUCUMXWEO-UHFFFAOYSA-N Ethene Chemical compound C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 claims description 2
- 229920000181 Ethylene propylene rubber Polymers 0.000 claims description 2
- 239000004743 Polypropylene Substances 0.000 claims description 2
- 150000001241 acetals Chemical class 0.000 claims description 2
- DQXBYHZEEUGOBF-UHFFFAOYSA-N but-3-enoic acid;ethene Chemical compound C=C.OC(=O)CC=C DQXBYHZEEUGOBF-UHFFFAOYSA-N 0.000 claims description 2
- KPUWHANPEXNPJT-UHFFFAOYSA-N disiloxane Chemical class [SiH3]O[SiH3] KPUWHANPEXNPJT-UHFFFAOYSA-N 0.000 claims description 2
- 239000005038 ethylene vinyl acetate Substances 0.000 claims description 2
- 229920001903 high density polyethylene Polymers 0.000 claims description 2
- 239000004700 high-density polyethylene Substances 0.000 claims description 2
- 229930195733 hydrocarbon Natural products 0.000 claims description 2
- 150000002430 hydrocarbons Chemical group 0.000 claims description 2
- 239000004816 latex Substances 0.000 claims description 2
- 229920000092 linear low density polyethylene Polymers 0.000 claims description 2
- 239000004707 linear low-density polyethylene Substances 0.000 claims description 2
- 229920001684 low density polyethylene Polymers 0.000 claims description 2
- 239000004702 low-density polyethylene Substances 0.000 claims description 2
- 229920003052 natural elastomer Polymers 0.000 claims description 2
- 229920001194 natural rubber Polymers 0.000 claims description 2
- 229920001155 polypropylene Polymers 0.000 claims description 2
- 229920005573 silicon-containing polymer Polymers 0.000 claims description 2
- 229920002379 silicone rubber Polymers 0.000 claims description 2
- 239000004945 silicone rubber Substances 0.000 claims description 2
- 239000006260 foam Substances 0.000 abstract description 13
- 239000010410 layer Substances 0.000 description 114
- 230000008569 process Effects 0.000 description 10
- 238000010586 diagram Methods 0.000 description 5
- 238000004519 manufacturing process Methods 0.000 description 5
- 239000000126 substance Substances 0.000 description 5
- 230000015572 biosynthetic process Effects 0.000 description 4
- 238000000465 moulding Methods 0.000 description 4
- 239000004433 Thermoplastic polyurethane Substances 0.000 description 3
- 238000005266 casting Methods 0.000 description 3
- 239000003795 chemical substances by application Substances 0.000 description 3
- 230000007547 defect Effects 0.000 description 3
- 230000002829 reductive effect Effects 0.000 description 3
- 229920002803 thermoplastic polyurethane Polymers 0.000 description 3
- RGSFGYAAUTVSQA-UHFFFAOYSA-N Cyclopentane Chemical compound C1CCCC1 RGSFGYAAUTVSQA-UHFFFAOYSA-N 0.000 description 2
- 230000002745 absorbent Effects 0.000 description 2
- 239000002250 absorbent Substances 0.000 description 2
- QWTDNUCVQCZILF-UHFFFAOYSA-N isopentane Chemical compound CCC(C)C QWTDNUCVQCZILF-UHFFFAOYSA-N 0.000 description 2
- 230000009467 reduction Effects 0.000 description 2
- 230000000717 retained effect Effects 0.000 description 2
- 239000004721 Polyphenylene oxide Substances 0.000 description 1
- 230000002730 additional effect Effects 0.000 description 1
- 230000004888 barrier function Effects 0.000 description 1
- 238000007664 blowing Methods 0.000 description 1
- 239000002131 composite material Substances 0.000 description 1
- 230000006835 compression Effects 0.000 description 1
- 238000007906 compression Methods 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 230000007812 deficiency Effects 0.000 description 1
- NKDDWNXOKDWJAK-UHFFFAOYSA-N dimethoxymethane Chemical compound COCOC NKDDWNXOKDWJAK-UHFFFAOYSA-N 0.000 description 1
- AFABGHUZZDYHJO-UHFFFAOYSA-N dimethyl butane Natural products CCCC(C)C AFABGHUZZDYHJO-UHFFFAOYSA-N 0.000 description 1
- 238000006073 displacement reaction Methods 0.000 description 1
- 230000008030 elimination Effects 0.000 description 1
- 238000003379 elimination reaction Methods 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- DMEGYFMYUHOHGS-UHFFFAOYSA-N heptamethylene Natural products C1CCCCCC1 DMEGYFMYUHOHGS-UHFFFAOYSA-N 0.000 description 1
- 239000011159 matrix material Substances 0.000 description 1
- 230000036961 partial effect Effects 0.000 description 1
- 230000002093 peripheral effect Effects 0.000 description 1
- 229920000570 polyether Polymers 0.000 description 1
- 238000003672 processing method Methods 0.000 description 1
- 239000002344 surface layer Substances 0.000 description 1
- 238000005303 weighing Methods 0.000 description 1
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
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- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
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- B32B2571/00—Protective equipment
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2201/00—Foams characterised by the foaming process
- C08J2201/02—Foams characterised by the foaming process characterised by mechanical pre- or post-treatments
- C08J2201/022—Foams characterised by the foaming process characterised by mechanical pre- or post-treatments premixing or pre-blending a part of the components of a foamable composition, e.g. premixing the polyol with the blowing agent, surfactant and catalyst and only adding the isocyanate at the time of foaming
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- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
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- C08J2300/26—Elastomers
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- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2375/00—Characterised by the use of polyureas or polyurethanes; Derivatives of such polymers
- C08J2375/04—Polyurethanes
- C08J2375/08—Polyurethanes from polyethers
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2383/00—Characterised by the use of macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing silicon with or without sulfur, nitrogen, oxygen, or carbon only; Derivatives of such polymers
- C08J2383/14—Characterised by the use of macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing silicon with or without sulfur, nitrogen, oxygen, or carbon only; Derivatives of such polymers in which at least two but not all the silicon atoms are connected by linkages other than oxygen atoms
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2385/00—Characterised by the use of macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing atoms other than silicon, sulfur, nitrogen, oxygen, and carbon; Derivatives of such polymers
- C08J2385/04—Characterised by the use of macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing atoms other than silicon, sulfur, nitrogen, oxygen, and carbon; Derivatives of such polymers containing boron
Definitions
- the present invention relates to methods for forming foamed polymeric articles and articles produced by such methods.
- the invention relates to a method of forming a foamed polymeric article comprising a foamed polymeric material sandwiched between two layers in a mold, wherein the polymeric material comprises a chemical blowing agent, and the expansion of the polymeric material during foaming causes the outer layers of the article to deform so as to provide good contact with the surfaces of the mold.
- the present invention further relates to foamed polymeric articles formed by the method of the invention having complex surface geometry and/or good continuity of the foam.
- Foamed polymeric articles have many uses, including providing cushioning for impact and vibration dampening, resistance to compression, deflection, friction reduction and the like.
- foamed polymeric articles having various simple structures may be suitable.
- more complex structures are required, for example if the foamed polymeric articles are intended to fit closely against structures having an uneven surfaces, such as body parts or complex mechanical components, or if additional properties are to be provided by the inclusion of regions having significantly different thicknesses, such as extra thickness to provide improved impact protection in certain areas and reduced thickness to provide greater flexibility in other areas.
- Such complex foamed polymeric articles may be produced as a single object or may be formed by combining smaller articles on a common base.
- US 201 1/0277923 discloses a molding system that is said to be suitable for molding very thick products by controlling the rate of mold closure and/or interrupting the mold closure.
- this process is restricted to the use of mechanically frothed foams, and is not applicable to chemically foamed polymeric materials, such as chemically foamed polyurethane.
- this process also relies on a vacuum system within the mold to help conform surface layers to the structure of the mold. Reject rates due to inconsistent foam structure and/or the presence of bubbles using the processes disclosed in US201 1/0277923 are not economically acceptable.
- a foamed polymeric article comprising a foamed polymeric material sandwiched between two layers, the method comprising the steps of:
- a layer to a mold comprising at least first and second sections, at least one of the sections comprising a mold cavity having a mold profile, the layer being applied to the section comprising the mold cavity such that the profile of the layer is smoother than the mold profile;
- the further layer may be applied to the section of the mold other than the section to which the layer has been applied, so that the step of applying the further layer onto the charge of polymeric material occurs by closing the mold, i.e. so that steps iii. and iv. are effectively a single step.
- the chemical foaming of the charge of polymeric material may begin as soon as the charge is applied to the layer, so that step v. begins at the same time as, or even before, the closing of the mold (step iv.). Preferably however, no more than 10% of the foaming is completed before the mold is fully closed.
- the smoother profile is such that the layer is substantially spaced apart from the mold cavity, and preferably the layer is spaced apart such that it does not contact an inner surface of the mold cavity.
- the profile of the layer is smoother than the mold profile, the charge of polymeric material may spread more evenly across the layer and, in particular, the formation of air bubbles between the polymeric material and the layer is completely avoided, or at least substantially reduced. This provides substantial improvements in the continuity of the foam, and the reduction or elimination of undesirable bubbles.
- the layer adheres well to the complex structure of the mold profile improving the definition of the surface structure of the foamed polymeric article.
- This step of the method is particularly facilitated by the inclusion of vents in the section of the mold comprising the mold cavity, the vents allowing air initially present between the layer and the mold profile to escape from the mold, so as to permit improved contact between the layer and the mold profile.
- the layer also creates a barrier between the polymeric material and the vents in the mold section, preventing the vents becoming blocked by the polymeric material, and avoids the need for release agents which can block vents, add extra cost and cause post process adhesion issues.
- the layer may be self-supporting in the mold section before foaming of the polymeric material.
- the layer is held under tension after being applied to the section of the mold comprising a mold cavity and preferably it is held taut, providing a good surface for the charge of polymeric material to spread over.
- the layer applied to the section of the mold comprising the mold cavity may comprise any material suitable to act as an outer layer of a foamed polymeric article.
- the layer comprises a polymer, textile and/or metal.
- the layer may also be formed from multiple layers of the same or different materials.
- the layer applied to the section of the mold comprising the mold cavity comprises a polymer comprising one or more materials selected from plastics, elastomeric materials, polyolefins, polyamides, polystyrenes, ethylene-vinyl acetates, nylons, polyesters, polyethylenes, polytetrafluroethylene, silicones, vinyls, polyurethanes, polyvinyl chloride, latex rubbers, synthetic rubbers, thermoplastic elastomers, or mixtures thereof.
- the layer comprises a textile which a woven or non-woven fabric comprising natural and/or artificial materials, preferably spandex or elastane, cordura, aramids, cotton or canvas.
- the layer applied to the section of the mold comprising the mold cavity may be any suitable thickness, for example 0.001 mm to 3 mm, such as 0.05 to 0.01 mm.
- the layer applied to the section of the mold comprising the mold cavity will have a relatively low tensile modulus, such that it will stretch under the typical pressures generated by the chemical foaming of the polymeric material, such as 40 to 60 psi.
- a greater range of materials and/or thicknesses may be used in the method of the present invention compared to prior art processes, as in most prior art cases (for example using a vacuum to conform the film to the mold surface) much lower pressures are generated.
- the additional pressure produced in the method of the present invention also enables higher definition of complex products to be achieved.
- the charge of polymeric material may be applied to the layer in the mold by any suitable method, for example by being poured or injected onto the layer.
- the charge of polymeric material is applied substantially in the middle of the layer, so that it spreads evenly across the layer during foaming.
- the charge of polymeric material may be applied to the layer as a single charge.
- the size of the charge applied to the layer will depend upon the size of the article or articles to be formed and the size of the mold.
- the charge of polymeric applied to the layer is sufficient to cover from 10 to 100% of the layer before the mold is closed.
- the polymeric material will fill from 80 to 110% of the mold cavity.
- any polymeric material capable of being chemically foamed to form a foamed polymeric article when sandwiched between two suitable layers may be used in the method of the present invention.
- the polymeric material is selected from ethylene vinyl acetate, an olefin polymer, an ethylene polymer, polypropylene, LDPE, HDPE, LLDPE, natural elastomer (e.g. latex), synthetic elastomer (e.g. silicone rubber, polyurethane, ethylene propylene rubber such as EPDM) or thermoplastic elastomer (e.g. polyester).
- the polymeric material comprises a polymer-based material exhibiting dilatancy, preferably a silicone polymer, for example a borated siloxane polymer, such as PBDMS.
- the foamed polymeric material is an elastic, energy absorbent material which exhibits a resistive load under deformation which increases with the rate of deformation, such as a composite material which comprises i) a first polymer-based material and ii) a second polymer-based material, different from i), which exhibits dilatancy in the absence of i), wherein the second polymer-based material ii) is entrapped in a matrix of the first polymer-based material i), and which is prepared by incorporating the second polymer- based material ii) with the first polymer-based material i) prior to foaming.
- Particularly suitable elastic, energy absorbent materials for use in the method of the present invention are disclosed in WO 03
- any suitable material may be used as the chemical blowing agent in the methods according to the present invention.
- a chemical blowing agent will cause the charge of polymeric material to foam and may also cause the resulting foam to cure and/or set.
- Suitable chemical blowing agents include hydrocarbons such as isopentane and cyclopentane or acetals such as dimethoxymethane If required, additional agents may also be included in the charge of polymeric material, such as separate cure/setting agents.
- concentration of chemical blowing agent used in the methods according to the present invention will depend upon the nature of the polymeric material and the chemical blowing agent and other factors, including the degree of foaming required and the molding conditions.
- suitable concentrations include from 0.1 wt% to 10 wt%, such as 3 wt% to 5 wt%.
- the further layer is applied to the section of the mold to which the layer has not been applied and is self-supporting and/or is held under tension, and preferably held taut.
- the further layer may comprise any material suitable to act as an outer layer of a foamed polymeric article.
- the further layer may be the same as or different to the layer applied to the section of the mold comprising a mold profile.
- the further layer comprises a polymer, textile and/or metal.
- the further layer may also be formed from multiple layers of the same or different materials.
- the further layer comprises a polymer comprising one or more materials selected from plastics, elastomeric materials, polyolefins, polyamides, polystyrenes, ethylene-vinyl acetates, nylons, polyesters, polyethylenes, polytetrafluroethylene, silicones, vinyls, polyurethanes, polyvinyl chloride, latex rubbers, synthetic rubbers, thermoplastic elastomers, or mixtures thereof.
- the further layer comprises a textile which a woven or non-woven fabric comprising natural and/or artificial materials, preferably spandex or elastane, cordura, aramids, cotton or canvas.
- the further layer may be any suitable thickness, for example 0.001 mm to 3 mm, such as 0.05 to 0.01 mm.
- the layer applied to the section of the mold comprising the mold cavity, or the further layer applied to the other mold section comprises or includes a layer of heat-sensitive adhesive, i.e. it may comprise a heat-sensitive adhesive or may be formed from a material that is not a heat-sensitive adhesive but to which a heat-sensitive adhesive is applied before, during or after the forming of the foamed polymeric article.
- a heat-sensitive adhesive on the outer surface of foamed polymeric article is particularly advantageous if the article is to be attached to a textile, as the heat sensitive-adhesive may be used to bond the article to the textile.
- spreading of the charge of polymeric material is caused by pressure from the mold, and particularly by the application of the further layer to the upper surface of the charge of polymeric material by the closing of the mold.
- the method according to the present invention comprises deforming at least one of the layers, preferably the further layer, to form a convex shape with respect to the mold.
- the deforming may be caused by a protrusion on the relevant mold section, preferably located substantially at the centre of the section.
- the protrusion is removable and/or retractable.
- the protrusion used to deform the layer may be actively removed/retracted during the method or may be caused to retract by the expansion of the polymeric material during foaming.
- the relatively raised portion of the further layer comes into contact with the charge of polymeric material during the closing of the mold before other sections of the further layer, and, where the relatively raised portion is substantially central, this will cause air present between the upper surface of the charge of polymeric material and the further layer to move laterally away from the point of contact.
- the combination of this step with the expansion of the polymeric material during foaming and the employment of a relatively smooth profile for the layer to which the charge of polymeric material is applied can totally eliminate, or at least substantially reduce, the formation of bubbles in foamed polymeric articles produced by the method.
- both sections of the mold comprise a mold cavity, enabling foamed polymeric articles having complex surface geometry on both the upper and lower surfaces to be produced, and undercuts in the geometry can be produced due to the central parting line where the mold shuts.
- at least one section of the mold is heated, for example to a temperature of from 25 to 120°C, such as from 30 to 100, for example 40 to 60°C.
- Any suitable mold residence time may be used in methodes according to the present invention, depending upon the materials used and the molding conditions. However, suitable mold residence times are from 2 to 15 minutes, such as 10 minutes.
- Methods according to the present invention can produce much greater pressures within the mold compared to processes in which the surface of films are conformed to the mold only by a vacuum, for example 4 to 6 times greater pressures.
- the closed mold may be held under vacuum, for example so that the vacuum aids in conforming the layer applied to the section comprising the mold cavity to the mold profile, and in this case pressures of 5 to 7 times greater than conventional in mold pressures can be produced. This extra force can be used to reproduce finer details in the mold or to push thicker, stronger films into the mold cavity compared to prior art processes.
- the present invention also provides a foamed polymeric article comprising a foamed polymeric material sandwiched between two layers formed according to the method of the present invention.
- foamed polymeric articles having very good foam consistency and with virtually no, or substantially reduced, undesirable bubbles may be produced.
- multiple parts are formed using a single tool, at least 20 parts can be produced all weighing within one gram of each other.
- foamed polymeric articles produced by the method of the present invention may have complex geometries, including very thin regions or even regions of effectively zero thickness.
- very small parts may be produced accurately, for example parts having a volume of less than 1 cm 3 and/or parts having widths of as low as 1 mm.
- the present invention further provides a protective pad formed from a foamed polymeric material according to the present invention.
- Such protective pads may be formed either as a single component having a complex surface geometry, or may be formed by combining a number of smaller components on a common base material.
- the present invention further provides a textile article comprising one or more foamed polymeric articles according to the present invention and/or one or more protective pads according to the present invention attached to a textile by a layer of heat- sensitive adhesive.
- the heat-sensitive adhesive may be applied to the foamed polymeric article or protective pad after it has been formed by a method according to the present invention or during the process of forming.
- one of the layers between which the foamed polymeric material is sandwiched may comprise or include a heat-sensitive adhesive.
- the foamed polymeric article or protective pad may be attached to the textile by placing it in contact with the textile so that the heat- sensitive adhesive contacts the textile, and then heating so that the heat-sensitive adhesive fuses the article or pad to the textile.
- Figure 1 is a schematic diagram depicting a first mold section having a layer applied thereto in a first stage of a method according to an embodiment of the present invention
- Figure 2 is a schematic diagram showing a second stage of a method according to the embodiment of the present invention
- Figure 3 is a schematic diagram showing a third stage of a method according to the embodiment of the present invention.
- Figure 4 is a schematic diagram showing a fourth stage of a method according to the embodiment of the present invention.
- Figure 5 is a schematic diagram showing a fourth stage of a method according to an alternative embodiment of the present invention.
- Example 1 illustrates the invention.
- a first stage of a method according to an embodiment of the present invention is illustrated in Figure 1.
- a first mold section 1 comprising a mold cavity 3 defined by a mold profile 5 is provided, and a first layer 7 comprising a thermoplastic polyurethane (Bemis OT100) is disposed over the mold cavity 3 so that the profile of the first layer 7 is smoother than the mold profile 5.
- Bemis OT100 thermoplastic polyurethane
- FIG. 2 A second stage in the method is shown in Figure 2.
- a second mold section 9 having a relatively smooth mold profile 1 1 is provided, and a second layer 13 comprising a thermoplastic polyurethane (Bemis OT100) is applied thereto.
- the second mold section 9 further comprises a retractable pin 15 which is extended so that the second layer 13 is deformed to form a convex shape with respect to the second mold section 9.
- a charge of polymeric material 17 is applied to the first layer 7 at substantially the centre thereof.
- the charge of polymeric material 17 comprises a two part polyether based thermoplastic polyurethane, comprising a PU system, such as modelling foam referenced as J-Foam 7087, marketed by Jacobson Chemicals Ltd., premixed with a dilatant and a chemical blowing agent.
- FIG. 3 A third stage in the method of the present invention is shown in Figure 3.
- the first mold section 1 and the second mold section 9 are brought into contact, closing the mold cavity 3, and at the same time the charge of polymeric material 17 is spread outwards, so as to substantially cover all of the first layer 7, which is partially extended into the mold cavity 3 but which does not fully fill the cavity, so that the first layer 7 is in only partial contact with the mold profile 5.
- the retractable pin 15 at least initially remains extended from the second mold section 9, so that the central region of the second layer 13 contacts the charge of polymeric material 17 before the peripheral region of the second layer 13. This facilitates spreading of the charge of polymeric material 17 across the surface of the first layer 7, and also displaces air present between the second layer 13 and the charge of polymeric material 17 laterally, so that it is not entrapped between the second layer 13 and the polymeric material 17.
- FIG. 4 A fourth stage of the method is shown in Figure 4. As shown in Figure 4, in the fourth stage illustrated, the retractable pin 15 has been displaced completely into the second mold section 9 so that the second layer 13 is flush with the mold profile 1 1 of the second mold section 9. Additionally, chemical foaming of the charge of polymeric material 17 has caused the polymeric material to expand so that the first layer 7 has been displaced fully into the mold cavity 3 and is in close contact with the mold profile 5 of the first mold section 1.
- the polymeric material 17 is retained in the mold for approximately 10 minutes. Following setting of the charge of polymeric material 17 a foamed polymeric article 19 is formed comprising a foamed polymeric material 17 sandwiched between the first layer 7 and the second layer 13.
- the foamed polymeric article 19 may be removed from the mold cavity 3.
- the foamed polymeric article has a substantially flat first surface and a second surface having a complex geometry, as defined by the mold profile 5 of the first mold section 1.
- the foamed polymeric article 19 has a substantially uniform consistency across the article and is substantially free of unwanted bubbles.
- the fourth stage of an alternative embodiment of a method according to the present invention is illustrated in Figure 5.
- the first mold section 1 corresponds generally to the first mold section 1 shown in Figures 1 to 4, and comprises a mold cavity (no longer visible) and a mold profile 5 having a complex geometry.
- the second mold section 21 corresponds generally to the second mold section 9 as shown in Figures 1 to 4 it differs therefrom, in that it also comprises a mold cavity (not visible) and a mold profile 23 having a complex surface geometry.
- a first layer 7 corresponding generally to the first layer used in the method shown in Figures 1 to 4 is applied to the first mold section 1 and a second layer 13 corresponding generally to the second layer 13 used in the method illustrated in Figures 1 to 4 is applied to the second mold section 21.
- the second layer 13 when the second layer 13 is applied to the second mold section 21 it does not initially protrude into the mold cavity of the second mold section 21 and does not contact the mold profile 23 of the second mold section 21.
- the displacement of the second layer 13 from the mold profile 23 may be facilitated by use of a retractable pin 15 present in the second mold section 21 ; however, if the second layer 13 is held taut the use of the retractable pin 15 is not necessary, and this may be retained in a retracted position within the second mold section 21.
- a charge of polymeric material 17 corresponding to the charge of polymeric material 17 discussed with respect to Figures 2 and 3 is applied to the first layer 7, without causing the first layer 7 to substantially protrude into the mold cavity of the first mold section 1.
- the second layer 13 is then brought into contact with the upper surface of the charge of polymeric material 17 by bringing the second mold section 21 into contact with the first mold section 1. This causes the charge of polymeric material 17 to spread across the surface of the first layer 7 and the second layer 13, so as to substantially cover both surfaces.
- the foaming of the charge of polymeric material 17 causes the material to expand, so that the first layer 7 protrudes into the mold cavity of the first mold section 1 and comes into close contact with the mold profile 5 of the first mold section 1.
- the expansion of the polymeric material during foaming also causes the second layer 13 to extend into the mold cavity of the second mold section 21 and to come into close contact with the mold profile 23 of the second mold section 21.
- foamed polymeric article 25 comprises a foamed polymeric material 17 sandwiched between the first layer 7 and second layer 13 and both the first layer 7 and second layer 13 have complex surface geometries.
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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Materials Engineering (AREA)
- Health & Medical Sciences (AREA)
- General Chemical & Material Sciences (AREA)
- Medicinal Chemistry (AREA)
- Polymers & Plastics (AREA)
- Organic Chemistry (AREA)
- Moulds For Moulding Plastics Or The Like (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
- Manufacture Of Porous Articles, And Recovery And Treatment Of Waste Products (AREA)
Abstract
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
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GB1809132.2A GB2559926B (en) | 2015-11-04 | 2016-11-04 | Method of forming foamed polymeric articles |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
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GB1519505.0 | 2015-11-04 | ||
GBGB1519505.0A GB201519505D0 (en) | 2015-11-04 | 2015-11-04 | Method of forming foamed polymeric articles |
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WO2017077332A1 true WO2017077332A1 (fr) | 2017-05-11 |
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PCT/GB2016/053458 WO2017077332A1 (fr) | 2015-11-04 | 2016-11-04 | Procédé de formation d'objets polymères moussés |
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GB (2) | GB201519505D0 (fr) |
WO (1) | WO2017077332A1 (fr) |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2020164947A1 (fr) * | 2019-02-12 | 2020-08-20 | Paltech | Procédé de moulage d'articles polymères dotés de noyau en mousse en sandwich |
CN114851460A (zh) * | 2022-04-25 | 2022-08-05 | 蜂巢能源科技股份有限公司 | 渐变弹性材料及其生产模具和生产方法以及方型电池 |
Families Citing this family (1)
Publication number | Priority date | Publication date | Assignee | Title |
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CN113929980B (zh) * | 2021-09-29 | 2023-08-01 | 东莞一贝核科技有限公司 | 一种高弹性复合高分子材料及其制备工艺 |
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JPS4856262A (fr) * | 1971-11-17 | 1973-08-07 | ||
US4891081A (en) * | 1985-12-04 | 1990-01-02 | Tokai Chemical Industries, Ltd. | Method for producing a foamed resin molding |
US5186777A (en) * | 1989-11-23 | 1993-02-16 | Skis Rossignol S.A. | Process for the manufacture of a composite molded structure, and especially of a ski |
EP0753389A2 (fr) * | 1995-07-14 | 1997-01-15 | MASCHINENFABRIK HENNECKE GmbH | Procédé pour la production des articles en mousse de polyuréthane |
GB2490734A (en) * | 2011-05-13 | 2012-11-14 | Mas Res And Innovation Pvt Ltd | Polyurethane foam composition and method of manufacturing a foam article |
-
2015
- 2015-11-04 GB GBGB1519505.0A patent/GB201519505D0/en not_active Ceased
-
2016
- 2016-11-04 GB GB1809132.2A patent/GB2559926B/en active Active
- 2016-11-04 WO PCT/GB2016/053458 patent/WO2017077332A1/fr active Application Filing
Patent Citations (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US2976577A (en) * | 1958-04-14 | 1961-03-28 | Gen Motors Corp | Process of making foam cored laminates |
JPS4856262A (fr) * | 1971-11-17 | 1973-08-07 | ||
US4891081A (en) * | 1985-12-04 | 1990-01-02 | Tokai Chemical Industries, Ltd. | Method for producing a foamed resin molding |
US5186777A (en) * | 1989-11-23 | 1993-02-16 | Skis Rossignol S.A. | Process for the manufacture of a composite molded structure, and especially of a ski |
EP0753389A2 (fr) * | 1995-07-14 | 1997-01-15 | MASCHINENFABRIK HENNECKE GmbH | Procédé pour la production des articles en mousse de polyuréthane |
GB2490734A (en) * | 2011-05-13 | 2012-11-14 | Mas Res And Innovation Pvt Ltd | Polyurethane foam composition and method of manufacturing a foam article |
Cited By (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2020164947A1 (fr) * | 2019-02-12 | 2020-08-20 | Paltech | Procédé de moulage d'articles polymères dotés de noyau en mousse en sandwich |
US11958218B2 (en) | 2019-02-12 | 2024-04-16 | Paltech | Process for moulding polymeric foam core sandwich articles |
CN114851460A (zh) * | 2022-04-25 | 2022-08-05 | 蜂巢能源科技股份有限公司 | 渐变弹性材料及其生产模具和生产方法以及方型电池 |
CN114851460B (zh) * | 2022-04-25 | 2023-06-20 | 蜂巢能源科技股份有限公司 | 渐变弹性材料及其生产模具和生产方法以及方型电池 |
Also Published As
Publication number | Publication date |
---|---|
GB201809132D0 (en) | 2018-07-18 |
GB2559926B (en) | 2021-12-08 |
GB201519505D0 (en) | 2015-12-16 |
GB2559926A (en) | 2018-08-22 |
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