WO2024051872A1 - Method of manufacturing reoriented foamed polyolefin sheets - Google Patents

Method of manufacturing reoriented foamed polyolefin sheets Download PDF

Info

Publication number
WO2024051872A1
WO2024051872A1 PCT/CZ2023/050059 CZ2023050059W WO2024051872A1 WO 2024051872 A1 WO2024051872 A1 WO 2024051872A1 CZ 2023050059 W CZ2023050059 W CZ 2023050059W WO 2024051872 A1 WO2024051872 A1 WO 2024051872A1
Authority
WO
WIPO (PCT)
Prior art keywords
plates
reoriented
blanks
thickness
foamed polyolefin
Prior art date
Application number
PCT/CZ2023/050059
Other languages
French (fr)
Inventor
Ondrej KRATKY
Original Assignee
Spur A. S.
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
Application filed by Spur A. S. filed Critical Spur A. S.
Publication of WO2024051872A1 publication Critical patent/WO2024051872A1/en

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
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/02—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by a sequence of laminating steps, e.g. by adding new layers at consecutive laminating stations
    • 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
    • B29C44/56—After-treatment of articles, e.g. for altering the shape
    • B29C44/5627—After-treatment of articles, e.g. for altering the shape by mechanical deformation, e.g. crushing, embossing, stretching
    • B29C44/5654—Subdividing foamed articles to obtain particular surface properties, e.g. on multiple modules
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/022—Particular heating or welding methods not otherwise provided for
    • B29C65/028—Particular heating or welding methods not otherwise provided for making use of inherent heat, i.e. the heat for the joining comes from the moulding process of one of the parts to be joined
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/10—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using hot gases (e.g. combustion gases) or flames coming in contact with at least one of the parts to be joined
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/1403—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation characterised by the type of electromagnetic or particle radiation
    • B29C65/1412—Infrared [IR] radiation
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/114—Single butt joints
    • B29C66/1142—Single butt to butt joints
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43—Joining a relatively small portion of the surface of said articles
    • B29C66/435—Making large sheets by joining smaller ones or strips together
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/727—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being porous, e.g. foam
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/731—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the intensive physical properties of the material of the parts to be joined
    • B29C66/7313—Density
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/735—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the extensive physical properties of the parts to be joined
    • B29C66/7352—Thickness, e.g. very thin
    • 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
    • B29C69/00—Combinations of shaping techniques not provided for in a single one of main groups B29C39/00 - B29C67/00, e.g. associations of moulding and joining techniques; Apparatus therefore
    • B29C69/001—Combinations of shaping techniques not provided for in a single one of main groups B29C39/00 - B29C67/00, e.g. associations of moulding and joining techniques; Apparatus therefore a shaping technique combined with cutting, e.g. in parts or slices combined with rearranging and joining the cut parts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D99/00—Subject matter not provided for in other groups of this subclass
    • B29D99/001—Producing wall or panel-like structures, e.g. for hulls, fuselages, or buildings
    • B29D99/0021—Producing wall or panel-like structures, e.g. for hulls, fuselages, or buildings provided with plain or filled structures, e.g. cores, placed between two or more plates or sheets, e.g. in a matrix
    • 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • 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
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/10—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material
    • B32B3/14—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material characterised by a face layer formed of separate pieces of material which are juxtaposed side-by-side
    • 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
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/10—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material
    • B32B3/18—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material characterised by an internal layer formed of separate pieces of material which are juxtaposed side-by-side
    • 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
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/16—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating
    • B32B37/18—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating involving the assembly of discrete sheets or panels only
    • 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
    • B32B5/02—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 structural features of a fibrous or filamentary layer
    • B32B5/12—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 structural features of a fibrous or filamentary layer characterised by the relative arrangement of fibres or filaments of different layers, e.g. the fibres or filaments being parallel or perpendicular to each other
    • 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
    • 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
    • B32B5/32—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 at least two layers being foamed and next to each other
    • 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
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/02—Physical, chemical or physicochemical properties
    • B32B7/022—Mechanical properties
    • 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
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/03—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers with respect to the orientation of features
    • 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
    • B29C2793/00—Shaping techniques involving a cutting or machining operation
    • B29C2793/0072—Shaping techniques involving a cutting or machining operation combined with rearranging and joining the cut parts
    • 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
    • B29C44/50—Feeding the material to be shaped into an open space or onto moving surfaces, i.e. to make articles of indefinite length using pressure difference, e.g. by extrusion or by spraying
    • 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
    • B32B2266/025—Polyolefin
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/72—Density

Definitions

  • This invention is related to reoriented polyolefin foamed sheets production, particularly semi-finished products (core sheets) for following sandwich boards manufacturing during which surface top layer ensuring reinforcement and/or protection against physical and chemical external effects and/or decorative function is laminated from both sides perpendicular to thickness direction.
  • core sheets semi-finished products
  • extruded polyolefin foam physically expanded by butane, propane, freon or CO2 in the form of film or square/rectangular profile has significantly higher compressive strength and modulus in the lengthwise (i.e. extrusion) direction than in the widthwise or thicknesswise directions. This is commonly used fact especially for multilayer lightweight sandwich boards which are composed of foamed core sheets with extrusion direction perpendicular to outer covering layers of final multilayer board.
  • Typical example of this technical solution is Chinese utility model CN216300437 focused on high strength polyethylene terephthalate (PET) composite boards containing core sheet made of PET foam transversely cut from PET sheet. Top frontal side of this core sheet is bonded by top hot melt layer to top layer made of nonwoven textile and further foamed sheet and finally covering surface layer is bonded to it. Bottom side of the core sheet is bonded to bottom side of nonwoven textile and further foamed sheet and finally covering surface layer is bonded to it. Covering surface layer can be film resistant to weather effects, ultraviolet light etc. Due to this fact, whole composite board is resistant to these effects. Aging resistance can be further adjusted according to specific requirements. Composite board is produced from PET materials, and due to thermal bonding of composite structure it is not susceptible to damage. However, this particular Chinese utility model as well as other openly published documents focused on similar topic have not in more detail described and thus technologically optimized method of core sheet production with extrusion direction perpendicular to outer covering layers of final the multilayer board. Summary of the Invention
  • Planar bonding of the blanks is with benefit realized by thermo contact (fusion) heating or hot air welding or infrared welding or gluing.
  • Transverse cut of final block is with benefit performed by resistance wire, band saw or high-speed wire.
  • Fig. la-c Simplified interpretation of orientation principle is depicted in Fig. la-c.
  • Fig. la dimensional changes of foamed structure element in orientation direction (most often lengthwise, i.e. orientation in extrusion direction) is shown.
  • Fig. lb horizontal cut of discrete foamed structure cell model before and after orientation is depicted.
  • oriented foam has significantly higher compression strength and compression modulus in direction of orientation than in other two directions (2 directions perpendicular to direction of orientation) - see scheme of discrete cell model after orientation process shown in Fig. 1c where polypropylene foam oriented in this way has mechanical parameters specified in Fig. 1c.
  • Compression strength and modulus in thicknesswise direction of this oriented foam can in the next step consist of additional reorientation process of the foam according to this invention significantly increase.
  • Dependence of compression strength and compression modulus on foam density for polypropylene foam in the orientation direction is depicted in Fig. 2 and Fig. 3, respectively.
  • This reorientation process can be applied immediately after previous orientation process from still uncooled foam or additionally from cooled foam wound into a coil or cut. It is also possible to process foams produced in advance in the form of boards combined from several elements of foam that have undergone an orientation process (typically, for example, boards prepared by welding several layers of foam polypropylene strip on top of each other or boards prepared by welding several rectangular profiles of foamed polyolefin next to each other).
  • Reoriented boards from foamed polyolefin with a width of 100 to 2600 mm, length of 100 to 15000 mm and thickness of 2 to 500 mm can be prepared by below mentioned manners. These boards can have density of 30 to 300 kg/m 3 .
  • Reoriented boards made of foamed polyolefin (e.g. polypropylene) produced by mentioned variants of the method according to the invention are primarily intended for the production of sandwich boards laminated on both sides perpendicular to thickness direction (i.e. to the direction of orientation) with a surface layer that has a reinforcing function and/or protective function against physical and chemical external influences and/or decorative function.
  • foamed polyolefin e.g. polypropylene
  • reoriented plates made of foamed polypropylene have a temperature of use between -40 to 140 °C and a processing temperature of up to 155 °C. They are characterized by chemical resistance, high resistance to moisture, high non-absorption, good thermal insulation properties, high impact strength and high resistance to fatigue stress.
  • Reoriented boards made of foamed polyolefin can be designed with increased resistance to UV radiation.
  • Reoriented boards made of foamed polyolefin can also be designed with increased fire resistance.
  • Fig. la schematic representation of the dimensional changes of the foamed structure element in the orientation direction
  • Fig. lb longitudinal section view of the discrete cell model of the foamed structure before and after orientation
  • Fig. 1c schematic representation of mechanical parameters during loading of a discrete cell model of oriented foamed structure of polypropylene foam
  • Fig. 2 dependence of compression strength on foam density of polypropylene foam in the direction of orientation during compression
  • Fig. 3 dependence of compression modulus on foam density of polypropylene foam in the direction of orientation during compression
  • Fig. 4 technological scheme of the method according to the invention in the variant of reorientation by layering an endless foamed polyolefin strip into a block followed by transverse cutting and joining into the required format
  • Fig. 5a technological scheme of the method according to the invention in the variant of reorientation by layering plates of foamed polyolefin into a block followed by transverse cutting and bonding into the required format
  • Fig. 5b schematic representation of the plates used in the reorientation variant according to Fig. 5a.
  • Fig. 6 technological scheme of the method according to the invention in the variant of reorientation by cyclic layering of foamed polyolefin into a block using residual heat after extrusion followed by transverse cutting and bonding into the required format
  • Fig. 7 technological scheme of the method according to the invention in the variant of reorientation with side bonding of foamed polypropylene to the block using residual heat after extrusion followed by transverse cutting and bonding into the required format.
  • FIG. 4 An exemplary embodiment of the method of manufacturing reoriented foamed polyolefin boards according to the invention, in the variant of reorientation by layering an endless foamed polyolefin strip into a block with subsequent transverse cutting and bonding into the required format is shown by the technological scheme in Fig. 4.
  • a strip of lengthwise oriented and calibrated foamed polyolefin with a thickness of 1 to 100 mm, a width of 100 to 2600 mm and a density of 30 to 300 kg/m 3 is continuously extruded or unwound and subsequently it is transversely cut on blanks of length 400 to 4000 mm, which are then welded by thermocontact (fusion) heating or hot air heating or infrared heating or gluing in plane B into a gradually formed block 4 with a thickness of 10 to 3000 mm containing 2 to 500 layers of blanks 3 of the original foamed strip 1.
  • the block 4_ is then laterally aligned, transversely cut C into plates 5 with a thickness of 2 to 500 mm and these plates 5 after trimming D of the contact edges 6_are then bonded E by welding or gluing in the transverse direction to an endless plate 7.
  • the transverse cutting C of the block 4 is performed by a resistance wire, band saw or high-speed wire
  • side alignment is performed by a resistance wire, band saw or high-speed wire or a milling cutter
  • trimming D of the contact edges 6 of plates 5 before bonding E is performed by cutting or milling.
  • the endless plate 7 is subsequently divided F into individual plates 8 of a final length of 100 to 15000 mm which then, after trimming G of the longitudinal edges 9 to a final width of 100 to 2600 mm, represent finished plates 10 with a reoriented structure.
  • Bonding E of the plates 5 with trimmed contact edges 6 is carried out by welding based on thermocontact (fusion) heating or hot air heating or infrared heating or gluing.
  • FIG. 5a An exemplary embodiment of the method of manufacturing reoriented foamed polyolefin boards according to the invention in the variant of reorientation by layering boards from foamed polyolefin into a block with subsequent cross-cutting and bonding into the required format is shown by the technological scheme in Fig. 5a.
  • lengthwise oriented foamed polyolefin sheets 2 with thickness of 5 to 1250 mm, width of 100 to 2600 mm, length of 400 to 4000 mm and density of 30 to 300 kg/m 3 are continuously fed.
  • These plates 2 are prepared beforehand by the longitudinal bonding of several rectangular elements 2a (1-200 elements in the h direction; 1-200 elements in the w direction) with a cross-sectional area of each element of at least 1000 mm 2 with a composition unequivocally in the direction of lengthwise orientation (see Fig. 5b).
  • the plates 2 are then planar bonded B by welding based on thermocontact (fusion) heating or hot air heating or infrared heating or gluing into a gradually created block 4 with a thickness of 10 to 3000 mm, containing 2 to 500 layers of plates 2.
  • the block 4 is then laterally aligned, transversely cut C into plates 5 with thickness of 2 to 500 mm, and these plates 5 are after trimming D of the contact edges 6 then bonded E by welding or gluing in the transverse direction to an endless plate 7.
  • the transverse cutting C of the block 4 is performed with a resistance wire, band saw or high-speed wire
  • side alignment is performed with a resistance wire, band saw or high-speed wire or a milling cutter
  • trimming D of the contact edges 6 of plates 5 before bonding E is performed by cutting or milling.
  • the endless plate 7 is subsequently divided F into plates 8 with a final length of 100 to 15000 mm which then, after trimming G of the longitudinal edges 9 to a final width of 100 to 2600 mm, represent finished plates 10 with a reoriented structure.
  • the bonding of the E plates 5 with trimmed contact edges 6 is carried out by welding based on thermocontact (fusion) heating or hot air heating or infrared heating or gluing.
  • FIG. 6 An exemplary embodiment of the method of manufacturing reoriented foamed polyolefin boards according to the invention in the variant of reorientation by cyclic layering of foamed polyolefin into a block using the residual heat after extrusion with subsequent transverse cutting and bonding into the required format, is shown in the technological scheme in Fig. 6.
  • a foamed polyolefin strip 1 with a thickness of 1 to 100 mm, a width of 100 to 1500 mm and a density of 30 to 300 kg/m 3 is continuously extruded and lengthwise oriented, calibrated K and subsequently divided transversely A for blanks 3 with a length of 400 to 4000 mm.
  • the welding of blanks 3 using the residual heat after extrusion is based on planar bonding B into a gradually created block 4 with a thickness of 10 to 3000 mm, containing 2 to 500 layers of blanks 3 of the original foamed strip 1 during which they are taken from storage conveyor of the extrusion line and cyclic layered by layering applicator Bl to block 4.
  • Hot air or infrared heating B2 is used to warm up the blanks before bonding B.
  • the block 4 is cooled and then laterally aligned by cutting with a resistance wire, band saw or high-speed wire or milling with a milling cutter, cross-cut C with a resistance wire, band saw or high-speed wire into plates 5 with a thickness of 2 to 500 mm, and these plates 5 are then after trimming D of contact edges 6 trimmed D by cutting or milling and bonded E by welding based on thermocontact (fusion) heating or hot air heating or infrared heating or gluing in the transverse direction to the endless plate 7.
  • the endless plate 7 is subsequently divided F into plates 8 with a final length of 100 to 15000 mm which then, after trimming G of the longitudinal edges 9 to a final width of 100 to 1500 mm represent finished plates 10 with a reoriented structure.
  • FIG. 7 An exemplary embodiment of the method of manufacturing reoriented foamed polyolefin boards according to the invention in the variant of reorientation with lateral bonding of foamed polypropylene to the block using the residual heat after extrusion with subsequent transverse cutting and bonding to the required format is shown in the technological diagram in Fig. 7.
  • a rectangular profile 1 of foamed polyolefin with thickness of 5 to 100 mm, width of 50 to 1000 mm and density of 30 to 300 kg/m 3 is continuously extruded and lengthwise oriented, calibrated K and transversely divided A into blanks 3 with a length of 400 to 4000 mm.
  • the blanks 3 are welded by using residual heat after extrusion and further they are planar bonded B into a gradually created block 4 with thickness of 50 to 1000 mm, containing side by side 2 to 500 layers of blanks 3 of the original foamed profile 1. During this, they are taken from stock conveyor of extrusion line, heated by hot air B2 or infrared heated, positioned and bonded to a continuous block 4a when passing through the input bonding conveyor B3 and compression conveyor B4 which is then cut B6 into individual blocks 4 after cooling on the cooling conveyor B5.
  • Each of the blocks 4 prepared in this way is then laterally aligned by trimming with a resistance wire, band saw or high-speed wire or by milling with a milling cutter, cross-cut C with a resistance wire, band saw or high-speed wire into plates 5 with thickness of 2 to 500 mm and these plates 5 are after trimming D of contact edges 6 by cutting or milling, bonded E by welding based on thermocontact (fusion) heating or hot air heating or infrared heating or gluing in the transverse direction to an endless plate 7.
  • the endless plate 7 is subsequently divided F into plates with a final length of 100 to 15000 mm which then, after trimming G of the longitudinal edges 9 to a final width of 100 to 2600 mm, represent finished plates 10 with a reoriented structure.
  • An exemplary embodiment of the method of manufacturing reoriented foamed polyolefin boards according to the invention is a variant of reorientation by layering an endless foamed polyolefin strip into a block followed by cross-cutting and bonding into the required format according to the technological scheme in Fig. 4.
  • a strip la of lengthwise oriented and calibrated foamed polyolefin with thickness of 1 to 100 mm, width of 100 to 2600 mm and density of 30 to 300 kg/m 3 is continuously extruded or unwound, and subsequently transversely divided into blanks 3 with length of 400 to 4000 mm, which are then planar bonded B by welding based on thermocontact (fusion) heating or hot air heating or infrared heating or gluing into a gradually produced block 4 with a thickness of 10 to 3000 mm, containing 2 to 500 layers of blanks 3 of the original foamed strip 1.
  • Block 4 is then laterally aligned, cross-cut C into plates 5 with thickness of 2 to 500 mm, and contact edges D of these plates are trimmed.
  • Cross-cutting C of block 4 is done with a resistance wire, band saw or high-speed wire
  • side trimming is done with a resistance wire, a band saw or a high-speed wire or a milling machine
  • the trimming D of contact edges 6 of the plates 5 is performed by cutting or milling.
  • the bonding E of the plates 5 with the trimmed contact edges 6 is then no longer performed in this variant.
  • the method of production of reoriented foamed polyolefin boards according to the invention is mainly intended for the preparation of semi-finished products (core boards) for the following production of sandwich boards.
  • core plate is laminated from both sides perpendicular to the thickness direction by a surface layer that has a reinforcing function and/or a protective function against physical and chemical external influences and/or a decorative function corresponding to its specific application.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Health & Medical Sciences (AREA)
  • Toxicology (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Laminated Bodies (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)

Abstract

The production method consisted of continuous extrusion or unwinding of a square or rectangular profile (la), or continuous extrusion or unwinding of lengthwise oriented and foamed polyolefin strip (lb) which is transversely divided into blanks (3) or continuous feeding of lengthwise oriented foamed polyolefin sheets. Blanks or plates are planar bonded by welding or gluing into a gradually created block (4). The block obtained in this way is subsequently transversely cut into sheets (5). After cutting of the longitudinal edges to the final width, these plates can already represent finished plates (10) with a reoriented structure, or they are further bonded by welding or gluing in the transverse direction to an endless plate which is then divided into plates of the final length which then, after cut of longitudinal edges to the final width represent finished boards with a reoriented structure.

Description

METHOD OF MANUFACTURING REORIENTED FOAMED POLYOLEFIN SHEETS
Field of Invention
This invention is related to reoriented polyolefin foamed sheets production, particularly semi-finished products (core sheets) for following sandwich boards manufacturing during which surface top layer ensuring reinforcement and/or protection against physical and chemical external effects and/or decorative function is laminated from both sides perpendicular to thickness direction.
Current State of the Art
Generally, extruded polyolefin foam physically expanded by butane, propane, freon or CO2 in the form of film or square/rectangular profile has significantly higher compressive strength and modulus in the lengthwise (i.e. extrusion) direction than in the widthwise or thicknesswise directions. This is commonly used fact especially for multilayer lightweight sandwich boards which are composed of foamed core sheets with extrusion direction perpendicular to outer covering layers of final multilayer board.
Typical example of this technical solution is Chinese utility model CN216300437 focused on high strength polyethylene terephthalate (PET) composite boards containing core sheet made of PET foam transversely cut from PET sheet. Top frontal side of this core sheet is bonded by top hot melt layer to top layer made of nonwoven textile and further foamed sheet and finally covering surface layer is bonded to it. Bottom side of the core sheet is bonded to bottom side of nonwoven textile and further foamed sheet and finally covering surface layer is bonded to it. Covering surface layer can be film resistant to weather effects, ultraviolet light etc. Due to this fact, whole composite board is resistant to these effects. Aging resistance can be further adjusted according to specific requirements. Composite board is produced from PET materials, and due to thermal bonding of composite structure it is not susceptible to damage. However, this particular Chinese utility model as well as other openly published documents focused on similar topic have not in more detail described and thus technologically optimized method of core sheet production with extrusion direction perpendicular to outer covering layers of final the multilayer board. Summary of the Invention
Above mentioned lack can be to as great extend overcome by reoriented foamed polyolefin sheets production method according to this invention. Its basic principle consists of: aa) continual extrusion or unwind of square or rectangular lengthwise oriented and calibrated polyolefin foamed profile with thickness of 5 to 200 mm, width of 100 to 400 mm and density of 30 to 300 kg/m3 followed by transverse cut on blanks with length of 400 to 4000 mm, ab) continual feeding of lengthwise oriented polyolefin foamed sheets with thickness of 5 to 1250 mm, width of 100 to 2600 mm, length of 400 to 4000 mm and density of 30 to 300 kg/m3 beforehand prepared by longitudinal bonding from more elements unequivocally in direction of lengthwise orientation, ac) continual extrusion or unwind of lengthwise oriented and calibrated polyolefin foamed strip with thickness of 1 to 100 mm, width of 100 to 2600 mm and density of 30 to 300 kg/m3 followed by transverse cut on parts with length of 400 to 4000 mm, b) blanks or sheets planar bonded by welding with the aid of residual heat from extrusion or gluing from which block with thickness of 10 to 3000 mm consisting of 2 to 200 layers of original blanks of foamed profile, strip or sheet is gradually created, c) block obtained in this way is after possible side alignment from top and other sides transversely cut on sheets with thickness of 2 to 500 mm with that da) these sheets after cut of longitudinal edges on final width of 100 to 2600 mm represents finished sheets with reoriented structure or db) in the case when side alignment of the block is not performed, these sheets are after trimming of contact edges bonded together by welding or gluing in transverse direction into infinite sheet which is then cut to individual sheets of final length of 100 to 15000 mm which after cut of longitudinal edges on final width of 100 to 2600 mm represents finished board with reoriented structure.
Planar bonding of the blanks is with benefit realized by thermo contact (fusion) heating or hot air welding or infrared welding or gluing.
Transverse cut of final block is with benefit performed by resistance wire, band saw or high-speed wire.
Contact edges of the sheets before bonding are trimmed by cutting or milling. Bonding of trimmed sheets is then with benefit performed by thermo contact (fusion) heating or hot air welding or infrared welding or gluing. Extruded physically foamed polyolefin (e.g. polypropylene) foam expanded by butane, propane, freon or CO2 in the form of film or square profile or rectangular profile can be during extrusion or just after extrusion oriented in extrusion direction.
During this orientation under higher temperature and force foamed cell is elongated in one direction and thus, cells are oriented into elongated shape. After orientation is performed, this oriented state is immediately fixed by cooling of the oriented foam.
Simplified interpretation of orientation principle is depicted in Fig. la-c. In Fig. la dimensional changes of foamed structure element in orientation direction (most often lengthwise, i.e. orientation in extrusion direction) is shown. In Fig. lb horizontal cut of discrete foamed structure cell model before and after orientation is depicted. Hereby oriented foam has significantly higher compression strength and compression modulus in direction of orientation than in other two directions (2 directions perpendicular to direction of orientation) - see scheme of discrete cell model after orientation process shown in Fig. 1c where polypropylene foam oriented in this way has mechanical parameters specified in Fig. 1c.
Compression strength and modulus in thicknesswise direction of this oriented foam can in the next step consist of additional reorientation process of the foam according to this invention significantly increase. Dependence of compression strength and compression modulus on foam density for polypropylene foam in the orientation direction is depicted in Fig. 2 and Fig. 3, respectively.
This reorientation process can be applied immediately after previous orientation process from still uncooled foam or additionally from cooled foam wound into a coil or cut. It is also possible to process foams produced in advance in the form of boards combined from several elements of foam that have undergone an orientation process (typically, for example, boards prepared by welding several layers of foam polypropylene strip on top of each other or boards prepared by welding several rectangular profiles of foamed polyolefin next to each other).
Reoriented boards from foamed polyolefin with a width of 100 to 2600 mm, length of 100 to 15000 mm and thickness of 2 to 500 mm can be prepared by below mentioned manners. These boards can have density of 30 to 300 kg/m3.
Reoriented boards made of foamed polyolefin (e.g. polypropylene) produced by mentioned variants of the method according to the invention are primarily intended for the production of sandwich boards laminated on both sides perpendicular to thickness direction (i.e. to the direction of orientation) with a surface layer that has a reinforcing function and/or protective function against physical and chemical external influences and/or decorative function.
Depending on the method of use, reoriented plates made of foamed polypropylene have a temperature of use between -40 to 140 °C and a processing temperature of up to 155 °C. They are characterized by chemical resistance, high resistance to moisture, high non-absorption, good thermal insulation properties, high impact strength and high resistance to fatigue stress.
Reoriented boards made of foamed polyolefin can be designed with increased resistance to UV radiation.
Reoriented boards made of foamed polyolefin can also be designed with increased fire resistance.
By using reoriented boards made of foamed polyolefin with suitable surface layers, significant weight savings in comparison to conventional board types can be achieved.
Furthermore, by using reoriented boards made of foamed polyolefin with suitable surface layers and binders, a significantly lower weight of the resulting sandwich boards can be achieved in comparison with commonly used wood boards and chipboards at similar strength and stiffness.
Brief Description of Drawings
The attached drawings used to clarify the principle of the invention in more detail are following:
Fig. la: schematic representation of the dimensional changes of the foamed structure element in the orientation direction,
Fig. lb: longitudinal section view of the discrete cell model of the foamed structure before and after orientation
Fig. 1c: schematic representation of mechanical parameters during loading of a discrete cell model of oriented foamed structure of polypropylene foam
Fig. 2: dependence of compression strength on foam density of polypropylene foam in the direction of orientation during compression,
Fig. 3: dependence of compression modulus on foam density of polypropylene foam in the direction of orientation during compression,
Fig. 4: technological scheme of the method according to the invention in the variant of reorientation by layering an endless foamed polyolefin strip into a block followed by transverse cutting and joining into the required format, Fig. 5a: technological scheme of the method according to the invention in the variant of reorientation by layering plates of foamed polyolefin into a block followed by transverse cutting and bonding into the required format,
Fig. 5b: schematic representation of the plates used in the reorientation variant according to Fig. 5a.
Fig. 6: technological scheme of the method according to the invention in the variant of reorientation by cyclic layering of foamed polyolefin into a block using residual heat after extrusion followed by transverse cutting and bonding into the required format,
Fig. 7: technological scheme of the method according to the invention in the variant of reorientation with side bonding of foamed polypropylene to the block using residual heat after extrusion followed by transverse cutting and bonding into the required format.
Examples of Invention Realization
Example 1
An exemplary embodiment of the method of manufacturing reoriented foamed polyolefin boards according to the invention, in the variant of reorientation by layering an endless foamed polyolefin strip into a block with subsequent transverse cutting and bonding into the required format is shown by the technological scheme in Fig. 4.
In this variant of the production of reoriented foamed polyolefin (specifically polypropylene) sheets, a strip of lengthwise oriented and calibrated foamed polyolefin with a thickness of 1 to 100 mm, a width of 100 to 2600 mm and a density of 30 to 300 kg/m3 is continuously extruded or unwound and subsequently it is transversely cut on blanks of length 400 to 4000 mm, which are then welded by thermocontact (fusion) heating or hot air heating or infrared heating or gluing in plane B into a gradually formed block 4 with a thickness of 10 to 3000 mm containing 2 to 500 layers of blanks 3 of the original foamed strip 1.
The block 4_is then laterally aligned, transversely cut C into plates 5 with a thickness of 2 to 500 mm and these plates 5 after trimming D of the contact edges 6_are then bonded E by welding or gluing in the transverse direction to an endless plate 7. The transverse cutting C of the block 4 is performed by a resistance wire, band saw or high-speed wire, side alignment is performed by a resistance wire, band saw or high-speed wire or a milling cutter, trimming D of the contact edges 6 of plates 5 before bonding E is performed by cutting or milling.
The endless plate 7 is subsequently divided F into individual plates 8 of a final length of 100 to 15000 mm which then, after trimming G of the longitudinal edges 9 to a final width of 100 to 2600 mm, represent finished plates 10 with a reoriented structure. Bonding E of the plates 5 with trimmed contact edges 6 is carried out by welding based on thermocontact (fusion) heating or hot air heating or infrared heating or gluing.
Example 2
An exemplary embodiment of the method of manufacturing reoriented foamed polyolefin boards according to the invention in the variant of reorientation by layering boards from foamed polyolefin into a block with subsequent cross-cutting and bonding into the required format is shown by the technological scheme in Fig. 5a.
In this variant of the production of reoriented foamed polyolefin (specifically polypropylene) sheets, lengthwise oriented foamed polyolefin sheets 2 with thickness of 5 to 1250 mm, width of 100 to 2600 mm, length of 400 to 4000 mm and density of 30 to 300 kg/m3 are continuously fed. These plates 2 are prepared beforehand by the longitudinal bonding of several rectangular elements 2a (1-200 elements in the h direction; 1-200 elements in the w direction) with a cross-sectional area of each element of at least 1000 mm2 with a composition unequivocally in the direction of lengthwise orientation (see Fig. 5b).
The plates 2 are then planar bonded B by welding based on thermocontact (fusion) heating or hot air heating or infrared heating or gluing into a gradually created block 4 with a thickness of 10 to 3000 mm, containing 2 to 500 layers of plates 2.
The block 4 is then laterally aligned, transversely cut C into plates 5 with thickness of 2 to 500 mm, and these plates 5 are after trimming D of the contact edges 6 then bonded E by welding or gluing in the transverse direction to an endless plate 7. The transverse cutting C of the block 4 is performed with a resistance wire, band saw or high-speed wire, side alignment is performed with a resistance wire, band saw or high-speed wire or a milling cutter, trimming D of the contact edges 6 of plates 5 before bonding E is performed by cutting or milling.
The endless plate 7 is subsequently divided F into plates 8 with a final length of 100 to 15000 mm which then, after trimming G of the longitudinal edges 9 to a final width of 100 to 2600 mm, represent finished plates 10 with a reoriented structure. The bonding of the E plates 5 with trimmed contact edges 6 is carried out by welding based on thermocontact (fusion) heating or hot air heating or infrared heating or gluing. Example 3
An exemplary embodiment of the method of manufacturing reoriented foamed polyolefin boards according to the invention in the variant of reorientation by cyclic layering of foamed polyolefin into a block using the residual heat after extrusion with subsequent transverse cutting and bonding into the required format, is shown in the technological scheme in Fig. 6.
In this variant of the production of reoriented foamed polyolefin (specifically polypropylene) sheets, a foamed polyolefin strip 1 with a thickness of 1 to 100 mm, a width of 100 to 1500 mm and a density of 30 to 300 kg/m3 is continuously extruded and lengthwise oriented, calibrated K and subsequently divided transversely A for blanks 3 with a length of 400 to 4000 mm.
The welding of blanks 3 using the residual heat after extrusion is based on planar bonding B into a gradually created block 4 with a thickness of 10 to 3000 mm, containing 2 to 500 layers of blanks 3 of the original foamed strip 1 during which they are taken from storage conveyor of the extrusion line and cyclic layered by layering applicator Bl to block 4. Hot air or infrared heating B2 is used to warm up the blanks before bonding B.
The block 4 is cooled and then laterally aligned by cutting with a resistance wire, band saw or high-speed wire or milling with a milling cutter, cross-cut C with a resistance wire, band saw or high-speed wire into plates 5 with a thickness of 2 to 500 mm, and these plates 5 are then after trimming D of contact edges 6 trimmed D by cutting or milling and bonded E by welding based on thermocontact (fusion) heating or hot air heating or infrared heating or gluing in the transverse direction to the endless plate 7.
The endless plate 7 is subsequently divided F into plates 8 with a final length of 100 to 15000 mm which then, after trimming G of the longitudinal edges 9 to a final width of 100 to 1500 mm represent finished plates 10 with a reoriented structure.
Example 4
An exemplary embodiment of the method of manufacturing reoriented foamed polyolefin boards according to the invention in the variant of reorientation with lateral bonding of foamed polypropylene to the block using the residual heat after extrusion with subsequent transverse cutting and bonding to the required format is shown in the technological diagram in Fig. 7.
In this version of reoriented foamed polyolefin production (specifically polypropylene) sheets, a rectangular profile 1 of foamed polyolefin with thickness of 5 to 100 mm, width of 50 to 1000 mm and density of 30 to 300 kg/m3 is continuously extruded and lengthwise oriented, calibrated K and transversely divided A into blanks 3 with a length of 400 to 4000 mm.
The blanks 3 are welded by using residual heat after extrusion and further they are planar bonded B into a gradually created block 4 with thickness of 50 to 1000 mm, containing side by side 2 to 500 layers of blanks 3 of the original foamed profile 1. During this, they are taken from stock conveyor of extrusion line, heated by hot air B2 or infrared heated, positioned and bonded to a continuous block 4a when passing through the input bonding conveyor B3 and compression conveyor B4 which is then cut B6 into individual blocks 4 after cooling on the cooling conveyor B5.
Each of the blocks 4 prepared in this way is then laterally aligned by trimming with a resistance wire, band saw or high-speed wire or by milling with a milling cutter, cross-cut C with a resistance wire, band saw or high-speed wire into plates 5 with thickness of 2 to 500 mm and these plates 5 are after trimming D of contact edges 6 by cutting or milling, bonded E by welding based on thermocontact (fusion) heating or hot air heating or infrared heating or gluing in the transverse direction to an endless plate 7.
The endless plate 7 is subsequently divided F into plates with a final length of 100 to 15000 mm which then, after trimming G of the longitudinal edges 9 to a final width of 100 to 2600 mm, represent finished plates 10 with a reoriented structure.
Example 5
An exemplary embodiment of the method of manufacturing reoriented foamed polyolefin boards according to the invention is a variant of reorientation by layering an endless foamed polyolefin strip into a block followed by cross-cutting and bonding into the required format according to the technological scheme in Fig. 4.
In this variant of the production of reoriented foamed polyolefin (specifically polypropylene) sheets a strip la of lengthwise oriented and calibrated foamed polyolefin with thickness of 1 to 100 mm, width of 100 to 2600 mm and density of 30 to 300 kg/m3 is continuously extruded or unwound, and subsequently transversely divided into blanks 3 with length of 400 to 4000 mm, which are then planar bonded B by welding based on thermocontact (fusion) heating or hot air heating or infrared heating or gluing into a gradually produced block 4 with a thickness of 10 to 3000 mm, containing 2 to 500 layers of blanks 3 of the original foamed strip 1. Block 4 is then laterally aligned, cross-cut C into plates 5 with thickness of 2 to 500 mm, and contact edges D of these plates are trimmed. Cross-cutting C of block 4 is done with a resistance wire, band saw or high-speed wire, side trimming is done with a resistance wire, a band saw or a high-speed wire or a milling machine, the trimming D of contact edges 6 of the plates 5 is performed by cutting or milling. The bonding E of the plates 5 with the trimmed contact edges 6 is then no longer performed in this variant.
The resulting plates 8 with a final length of 10 to 3000 mm then, after trimming G of the longitudinal edges 9 to a final width of 100 to 2600 mm, represent finished plates 10 with a reoriented structure.
Industrial Applicability
The method of production of reoriented foamed polyolefin boards according to the invention is mainly intended for the preparation of semi-finished products (core boards) for the following production of sandwich boards. In them, core plate is laminated from both sides perpendicular to the thickness direction by a surface layer that has a reinforcing function and/or a protective function against physical and chemical external influences and/or a decorative function corresponding to its specific application.

Claims

P A T E N T C L A I M S A method of manufacturing reoriented foamed polyolefin boards, especially semifinished products for the production of sandwich boards, laminated from both sides perpendicular to the thickness direction with a surface layer having reinforcing function and/or a protective function against physical and chemical influences and/or a decorative function, characterized by aa) continuous extrusion or unwinding of a square or rectangular profile (la) of lengthwise oriented and calibrated foamed polyolefin with thickness of 5 to 200 mm, width of 100 to 400 mm and density of 30 to 300 kg/m3 and subsequent transverse dividing (A) into blanks (3) with a length of 400 to 4000 mm, ab) continuous feeding of lengthwise oriented foamed polyolefin plates (2) with thickness of 5 to 1250 mm, width of 100 to 2600 mm, length of 400 to 4000 mm and density of 30 to 300 kg/m3 prepared beforehand by longitudinal bonding of several elements (2a) with a composition unequivocally in the direction of lengthwise orientation, ac) continuous extrusion or unwinding of a lengthwise oriented and calibrated foamed polyolefin strip (lb) with thickness of 1 to 100 mm, width of 100 to 2600 mm and density of 30 to 300 kg/m3 and then transverse dividing (A) into blanks (3) of length 400 up to 4000 mm, b) planar bonding of blanks (3) or plates (2) by welding (B) with the possible use of residual heat after extrusion or gluing into a gradually created block (4) with a thickness of 10 to 3000 mm, containing 2 to 500 layers of blanks of the original foamed profile, strip or plate, c) cross-cutting (C) of the block (4) obtained in this way (after possible side alignment from top and other sides) into plates (5) with thickness of 2 to 500 mm with the fact that da) these plates (5) then after trimming (G) of longitudinal edges (9) to a final width of 100 to 2600 mm, represent finished plates (10) with a reoriented structure or db) these plates (5) are after trimming (D) of the contact edges (6) and if the side alignment of the block has not been performed, bonded (E) by welding or gluing in the transverse direction to the endless plate (7) which is subsequently divided (F) into plates (8) with a final length of 100 to 15000 mm and then they after trimming (G) of the longitudinal edges (9) to final width of 100 to 2600 mm represent finished plates (10) with a reoriented structure. The production method according to claim 1, characterized by fact that the blanks (3) are planar bonded (B) by welding based on thermocontact fusion heating or hot air heating or infrared heating or gluing. The production method according to claim 1, characterized by fact that the lateral alignment of the resulting block (4) is performed by a resistance wire, a band saw or a high-speed wire or a milling cutter. The production method according to claim 1, characterized by the fact that the transverse cutting (C) of the resulting block (4) is performed with a resistance wire, a band saw or a high-speed wire. The production method according to claim 1, characterized by the fact that trimming (D) of the contact edges (6) of the plates (5) before bonding (E) is performed by cutting or milling. The production method according to claim 1, characterized by fact that the bonding (E) of the plates with the trimmed contact edges (6) is performed by welding based on thermocontact fusion heating or hot air heating or infrared heating or gluing.
PCT/CZ2023/050059 2022-09-07 2023-09-06 Method of manufacturing reoriented foamed polyolefin sheets WO2024051872A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
CZPV2022-379 2022-09-07
CZ2022-379A CZ309826B6 (en) 2022-09-07 2022-09-07 The method of production of reoriented lightweight polyolefin sheets

Publications (1)

Publication Number Publication Date
WO2024051872A1 true WO2024051872A1 (en) 2024-03-14

Family

ID=88506857

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/CZ2023/050059 WO2024051872A1 (en) 2022-09-07 2023-09-06 Method of manufacturing reoriented foamed polyolefin sheets

Country Status (2)

Country Link
CZ (1) CZ309826B6 (en)
WO (1) WO2024051872A1 (en)

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5462623A (en) * 1992-05-04 1995-10-31 Webcore Technologies, Inc. Method of production of reinforced foam cores
US20110165363A1 (en) * 2008-07-30 2011-07-07 3A Technology & Management Ltd. Foamed plastics material panel
EP2653287A1 (en) * 2012-04-20 2013-10-23 URSA Insulation, S.A. Insulating panel and method of manufacturing of the same
US9533468B2 (en) * 2012-03-26 2017-01-03 Airex Ag Structural element and method for the production thereof

Family Cites Families (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20060060295A1 (en) * 2004-09-20 2006-03-23 Chih-Chun Hsu [method of manufacturing plastic foam powder puff]
JP6860977B2 (en) * 2016-03-30 2021-04-21 安積濾紙株式会社 Composite material using phase change substance, its manufacturing method and its arrangement method
CN209126201U (en) * 2018-12-04 2019-07-19 国塑机械(上海)有限公司 A kind of integrating device of PE sheet production line and PVC foam board assembly line
WO2020202908A1 (en) * 2019-04-05 2020-10-08 阿波製紙株式会社 Thermally conductive sheet and method for manufacturing same

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5462623A (en) * 1992-05-04 1995-10-31 Webcore Technologies, Inc. Method of production of reinforced foam cores
US20110165363A1 (en) * 2008-07-30 2011-07-07 3A Technology & Management Ltd. Foamed plastics material panel
US9533468B2 (en) * 2012-03-26 2017-01-03 Airex Ag Structural element and method for the production thereof
EP2653287A1 (en) * 2012-04-20 2013-10-23 URSA Insulation, S.A. Insulating panel and method of manufacturing of the same

Also Published As

Publication number Publication date
CZ2022379A3 (en) 2023-11-08
CZ309826B6 (en) 2023-11-08

Similar Documents

Publication Publication Date Title
US11472153B2 (en) Continuous honeycomb core material, honeycomb core sandwich composite panel and method and device for preparing same
US5834082A (en) Reinforced foam cores and method and apparatus of production
US5589243A (en) Reinforced foam cores and method and apparatus of production
US20070295457A1 (en) Process and apparatus for manufacturing a honeycomb composite material
US5462623A (en) Method of production of reinforced foam cores
US20070256379A1 (en) Composite panels
US4496024A (en) Sound absorption panel and method of making
WO2021128407A1 (en) Honeycomb core sandwich composite panel and manufacturing method therefor, and device
US9457500B2 (en) Production of extruded foam
MX9706921A (en) Polyisocyanurate boards with reduced moisture absorbency and lower air permeability and related methods.
US20110033655A1 (en) Energy saving honeycomb having enhanced strength
EP2686156B1 (en) Sandwich panel with a core of structural foam and manufacture thereof
US11192316B2 (en) Hierarchical honeycomb core with sandwich cell walls
EP2809489B1 (en) Building panel comprising a lamella core
WO2024051872A1 (en) Method of manufacturing reoriented foamed polyolefin sheets
EP0844929B1 (en) Reinforced foam cores
US20080202672A1 (en) Method of Making Product From Fusible Sheets and/or Elements
CA2472684C (en) Process and apparatus for manufacturing a honeycomb composite material
Pflug et al. Continuously produced honeycomb cores
CN110641098B (en) Device and method capable of continuously producing honeycomb sandwich and sandwich composite plate
CN113635616A (en) Outdoor board structure taking waste template as base material and production process
US20120200041A1 (en) Method of manufacturing archery target
Pflug et al. Honeycomb core materials: New concepts for continuous production
CN113071129B (en) Hexagonal honeycomb core material with vertical gluten and manufacturing method thereof
WO2008035097A1 (en) Method and apparatus for manufacturing thermoformed components comprising a core between continuous films

Legal Events

Date Code Title Description
121 Ep: the epo has been informed by wipo that ep was designated in this application

Ref document number: 23793230

Country of ref document: EP

Kind code of ref document: A1