CN102076425A - 加压涂覆***、方法和装置 - Google Patents

加压涂覆***、方法和装置 Download PDF

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CN102076425A
CN102076425A CN2009801253870A CN200980125387A CN102076425A CN 102076425 A CN102076425 A CN 102076425A CN 2009801253870 A CN2009801253870 A CN 2009801253870A CN 200980125387 A CN200980125387 A CN 200980125387A CN 102076425 A CN102076425 A CN 102076425A
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mold tool
coating
pressue device
compression chamber
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戈登·L·金
唐·A·帕特森
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    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
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    • B05C9/00—Apparatus or plant for applying liquid or other fluent material to surfaces by means not covered by any preceding group, or in which the means of applying the liquid or other fluent material is not important
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    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
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    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C48/12—Articles with an irregular circumference when viewed in cross-section, e.g. window profiles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/88—Thermal treatment of the stream of extruded material, e.g. cooling
    • B29C48/90—Thermal treatment of the stream of extruded material, e.g. cooling with calibration or sizing, i.e. combined with fixing or setting of the final dimensions of the extruded article
    • 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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/88—Thermal treatment of the stream of extruded material, e.g. cooling
    • B29C48/90—Thermal treatment of the stream of extruded material, e.g. cooling with calibration or sizing, i.e. combined with fixing or setting of the final dimensions of the extruded article
    • B29C48/908—Thermal treatment of the stream of extruded material, e.g. cooling with calibration or sizing, i.e. combined with fixing or setting of the final dimensions of the extruded article characterised by calibrator surface, e.g. structure or holes for lubrication, cooling or venting
    • 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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/88—Thermal treatment of the stream of extruded material, e.g. cooling
    • B29C48/911—Cooling
    • B29C48/9135—Cooling of flat articles, e.g. using specially adapted supporting means
    • B29C48/915—Cooling of flat articles, e.g. using specially adapted supporting means with means for improving the adhesion to the supporting means
    • B29C48/916—Cooling of flat articles, e.g. using specially adapted supporting means with means for improving the adhesion to the supporting means using vacuum
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    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05C—APPARATUS FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05C11/00—Component parts, details or accessories not specifically provided for in groups B05C1/00 - B05C9/00
    • B05C11/10—Storage, supply or control of liquid or other fluent material; Recovery of excess liquid or other fluent material
    • B05C11/1042—Storage, supply or control of liquid or other fluent material; Recovery of excess liquid or other fluent material provided with means for heating or cooling the liquid or other fluent material in the supplying means upstream of the applying apparatus
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05C—APPARATUS FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05C3/00—Apparatus in which the work is brought into contact with a bulk quantity of liquid or other fluent material
    • B05C3/005—Apparatus in which the work is brought into contact with a bulk quantity of liquid or other fluent material incorporating means for heating or cooling the liquid or other fluent material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/15—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor incorporating preformed parts or layers, e.g. extrusion moulding around inserts
    • B29C48/154—Coating solid articles, i.e. non-hollow articles
    • 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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/88—Thermal treatment of the stream of extruded material, e.g. cooling
    • B29C48/90—Thermal treatment of the stream of extruded material, e.g. cooling with calibration or sizing, i.e. combined with fixing or setting of the final dimensions of the extruded article
    • B29C48/904—Thermal treatment of the stream of extruded material, e.g. cooling with calibration or sizing, i.e. combined with fixing or setting of the final dimensions of the extruded article using dry calibration, i.e. no quenching tank, e.g. with water spray for cooling or lubrication
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2711/00—Use of natural products or their composites, not provided for in groups B29K2601/00 - B29K2709/00, for preformed parts, e.g. for inserts
    • B29K2711/14—Wood, e.g. woodboard or fibreboard

Abstract

涂覆***(100)包括模具工具(110)和加压装置(120)，模具工具(110)配置成把涂层材料涂覆到正在穿过模具工具的基材(130)，加压装置(120)附接到模具工具并形成加压室。加压装置配置成接收来自模具工具的基材并控制加压室中的基材周围的压力。在某些实施方式中，模具工具形成涂覆室并配置成把涂层材料涂覆到在涂覆室中的基材的至少一个表面上。

Description

加压涂覆***、方法和装置
相关申请
本申请要求于2008年7月1日提交的美国专利申请系列第12/166,223号的优先权，该美国专利申请以其相应整体通过引用并入。
背景
把涂层涂覆到基材表面的常规工艺具有局限性。例如，一些标准的涂覆工艺需要使用溶剂、静电吸附或最后的加热阶段，这通常增加费用并限制生产能力。
而且，某些常规涂覆工艺仅适合把特定物质涂覆到特定基材。例如，利用高温的涂覆工艺对于把涂层涂覆到含有相当多水分的基材来说是不切实际的，因为高温将导致水分变成蒸汽以及基材和/或涂层的“蒸汽逃逸(steam off)”。该“蒸汽逃逸”效应可引起涂层和涂覆产品的缺陷。因此，例如“蒸汽逃逸”效应可能阻碍某些涂敷工艺和/或带有某些基材的物质诸如一些木材产品或基于木材的产品(如装饰性模塑或其他修整木工产品)的使用。
附图简述
附图图示了本文描述的原理的各种实施方式并且是说明书的一部分。所图示的实施方式仅仅是例子，且并不限制本公开内容或权利要求的范围。
图1是图示根据本文描述的原理的示例性的加压涂覆***的透视图。
图2是根据本文描述的原理的包括在图1的加压***中的模具工具的内部的视图。
图3是根据本文描述的原理的包括在图1的加压***中的加压装置的剖视侧视图。
图4是根据本文描述的原理的包括在图1的加压***中的加压装置的透视图。
图5是根据本文描述的原理的包括在图1的加压***中的加压装置的另一个透视图。
图6是根据本文描述的原理的包括在图1的加压***中的加压装置的分解透视图。
图7图示了根据本文描述的原理的另一个示例性的加压和涂覆***。
图8图示了根据本文描述的原理的示例性的加压和涂覆方法。
详述
公开了用于把涂层涂覆到基材表面的示例性的加压和涂覆***、方法和装置。加压***、方法和装置可用作用于把涂层涂覆到基材表面的***、方法和装置的一部分。在某些实施中，加压***、方法和装置可以帮助扩大涂覆***、方法和装置的能力，例如通过扩大可实际涂覆的基材和/或可涂覆到基材的涂层材料的范围，以及减小或消除错误和缺陷的出现。
根据本文公开的原理，一种或多种合适的涂层材料可以被涂覆到基材表面。合适的涂层材料可以包括但不限于诸如液体塑料的流体态的材料，包括配置成粘附到特定基材如木材的塑料。在某些实施方式中，涂层材料包括以固态(如小球或粉末)或液态的涂层材料，可以在把涂层材料涂覆到基材表面的准备时被预处理。这可以包括加热涂层材料。例如，固态的涂层材料可以被加热到液态以便涂覆到基材表面。
涂层材料可以包括但不限于丙烯酸类树脂、聚酯、聚丙烯、聚乙烯、聚氯乙烯(PVC)、聚烯烃、ABS、ASA或上述中的任一种的合金。另外，涂层材料可以包括其他材料，包括但不限于彩色颜料、紫外线稳定剂、乳化剂、橡胶和其他对涂覆到基材的涂层提供持久的和/或装饰性的光洁度有潜在的帮助的其他种类稳定剂。可以主要用作对基材的粘合剂的携带块体的材料(bulk carrying material)可以包括但不限于丙烯酸类树脂、聚酯等。在一些涂覆应用中，携带块体的材料通常构成涂层材料的约百分之七十至百分之八十(70％-80％)，颜料通常构成涂层材料的约百分之十(10％)，并且涂层材料的剩余百分之十至百分之二十(10％-20％)包括紫外线稳定剂、乳化剂以及上述提到的其他成分中的任一种。
根据本文描述的原理，涂层材料可被涂覆到任何合适的基材的表面。可被涂覆的基材的例子包括但不限于木材表面、木材、无疵木材、天然木材、木材混合产品、基于木材的产品、中密度纤维板(MDF)、刨花板、塑料、金属、金属型物体、玻璃、基于玻璃的产品、玻璃纤维、天然产品、合成产品以及其他基本上刚性使得其形状在其经受涂覆工艺时被维持的任何其他合适的物体。在某些涂覆应用中，可使用本文描述的原理把诸如熔融的塑料的涂层涂覆到诸如木材产品或类似物的基材的表面。
现转向图，图1图示了示例性的加压涂覆***100(或简称“***100”)。***100包括模具工具110和加压装置120，模具工具110和加压装置120可相互附接，如图1所示。基材130可穿过模具工具110和加压装置120。图1显示基材130的已经穿过模具工具110和加压装置120并从加压装置120出来的一部分。在所图示的例子中，基材130包括装饰性修整木工产品(如，具有装饰性轮廓的模塑)。这仅仅是说明性的。***100可配置成把一种或多种涂层材料涂覆到任何合适的基材，包括上述列出的那些中的任何一种。
模具工具110可配置成当基材130穿过模具工具110时把涂层材料涂覆到基材130。模具工具110可包括任何机构并采用适合于把涂层材料涂覆到基材130的任何技术。在某些实施方式中，例如，液体涂层材料可被聚集并挤出在模具工具110内的基材130的至少一个表面上。
图2图示第一模具壳210和第二模具壳220，两个模具壳可相互附接以形成具有在其中的腔230的模具工具110的至少一部分。如图2所示，第一模具壳210和第二模具壳220每个可形成基材130可以穿过的孔240。在所图示的例子中，孔240被成形为符合基材130的轮廓。
在模具工具110内形成的腔230或腔230的至少一部分可称为涂覆室，在涂覆室内涂层材料可被涂覆到基材130。在某些实施方式中，模具工具110可配置成接收涂层材料，如以涂层材料进料器250的方式。涂层材料可在模具工具110内的涂覆室的至少一部分中积累。当基材130穿过涂覆室时，涂层材料被涂覆到基材130的至少一个表面。
在某些实施方式中，模具工具110可以被加热。模具工具110可以任何合适的方式被加热，如通过加热元件260连接到加热源。在某些实施方式中，模具工具110可配置成被加热至适合于把涂层材料涂覆到基材130的温度。例如，当模具工具110配置成把涂层材料挤出到涂覆室内的基材130的至少一个表面上时，模具工具110可被加热到有助于挤出的温度。
虽然图2图示了模具工具110的示例性部件，但是这个例子仅仅是说明性的。其他合适的模具工具110和涂覆装置或工艺可以用于其他实施方式中。例如，模具工具110可以包括和/或采用把涂层材料涂覆到基材130的任何合适的机构和/或工艺。
在某些实施中，涂层材料可以以2003年12月9日授权的且名称为“Method and Apparatus for Extruding a Coating Upon a Substrate Surface”(“用于将涂层挤出到基材表面上的方法和装置”)的美国专利第6,660,086号描述的方式中的任何一种被涂覆到基材130，美国专利第6,660,086号的内容由此以其整体通过引用并入。根据‘086专利，涂层材料可被加热到流体态并提供到包括腔的模具(如，见‘086专利的图3、4和9中的参考数字56)，涂层材料可以以流体态在腔内积累。模具包括具有匹配基材的二维轮廓的二维轮廓的孔。基材的尺寸可以被调整以适合孔轮廓和涂覆到基材的涂层光洁度(coating finish)。基材穿过模具，与匹配模具的轮廓相符合。如‘086专利描述的，当基材穿过模具轮廓时，涂层材料以受控的方式被涂覆到基材的表面。在某些实施中，模具工具110可以包括和/或配置成类似‘086专利中描述的模具(如，见‘086专利的图3、4和9中的参考数字56)。
在某些实施中，当流体态的涂层材料被提供到模具工具110并且基材130穿过模具工具110时，在模具工具110内可以形成加压环境。在某些涂覆应用中，模具工具110内的压力水平可以是约二百至八百磅每平方英寸(200-800psi)。另外，模具内的环境可以经受高温。这至少部分是由于涂层材料被加热到流体态和/或模具工具110被加热。在某些涂覆应用中，模具工具110内的温度可达到约三百至六百华氏温度(300-600℉)。这些范围仅仅是说明性的而不是限制性的。其他温度和压力范围可以出现于其他涂覆应用和实施方式中。
在没有如图1所示的附接到模具工具110的加压装置120的情况下，当涂覆过的基材130离开模具工具110的出口孔240时，涂覆过的基材130可以经受环境上的突变，突变包括例如从模具工具110中的加压环境到大气压力的压力的突变和/或从模具工具110中的高温到室温的环境温度的突降。这些环境压力和/或环境温度的突变中的一个或多个可以显著影响已经涂覆到基材130表面的涂层的品质。例如，各种基材130可以包括不同量的水分。基材130中存在的水分越多，基材130就越容易对环境突变作出反应。例如，当这样的基材130经受诸如可以在模具工具110中存在的高温和高压环境时，高压会阻止水分在高温下转变成蒸汽。即高压可以提高水分的沸点，以致高温不能使水分在模具工具110中沸腾。然而，当基材130离开模具工具110并且在没有时间足够冷却的情况下突然经受大气压力时，水分中的至少一些可以转变成蒸汽和基材130的“蒸汽逃逸”。这可使涂层变形，包括在涂层中引入气泡、波纹和洞。因而，虽然涂覆工艺可以非常适宜在一些基材130上涂覆某些涂层材料，但对于涂覆含有相对较高含量的水分的其他基材130，或使用某些涂层材料来说，同样的涂敷工艺可能不是切合实际的选择。
如图1所示，加压装置120可在***100中实施，并且在某些例子中可以扩大可以在涂覆工艺中使用的基材130和/或涂层材料的种类，包括在如果涂覆工艺中没有采用加压装置120的情况下把涂层涂覆到会有另外的“蒸汽逃逸”的具有水分含量的基材130时，使加压涂覆工艺成为切合实际的选择。
如图1所示，加压装置120可附接到模具工具110，并配置成当基材130离开模具工具110时接收来自模具工具110的基材130。加压装置120可形成加压室并且可包括和/或采用任何合适的技术以加压和/或控制加压室内的压力。例如，空气或一种或多种其他气体成分可被迫使通过加压装置120中的一个或多个孔进入加压室。图1显示加压装置120的侧板内形成的孔140。诸如空气软管和压力计的一个或多个加压工具可附接到孔140，使得加压室中的空气压力(air pressure)可被控制和监测。空气压缩机或其他合适的空气源可用来迫使空气通过孔140并进入加压室。在某些实施方式中，加压装置120的相对的侧板中可包括另一个孔，并且空气可被迫使通过两个孔140进入加压室。使加压室加压的这些例子仅仅是说明性的。其他合适的加压工具和工艺可包括和/或使用在其他实施方式中。
装置120的加压室中的压力可被设置和/或维持在任何合适的水平。在某些应用中，加压室中的压力可维持在大气压力和模具工具110的涂覆室内的压力之间的水平。对于某些示例性的应用，使用范围在约五磅至八十磅每平方英寸(5-80psi)的压力水平。在其他示例性的应用中，使用范围在约十磅至五十磅每平方英寸(10-50psi)的压力水平。然而，这些范围仅仅是说明性的而不是限制性的。其他合适的压力水平或压力水平的范围可在其他应用中使用。
加压装置120可以以适合于维持加压室内的受控的空气压力的任何方式附接到模具工具110。装置120附接到模具工具110可形成在模具工具110的外面(outer face)(如，模具工具110的模具板的外面)和加压装置120的外表面之间的密封(如，空气压力密封(air pressure seal))。图3图示了***100中的加压装置120的剖视侧视图。如所示，加压装置120的壁严密地附接于模具工具110的外面。在某些示例性的实施方式中，装置120的壁以形成适合于维持加压室中的受控的空气压力的密封的方式紧固至模具工具110。加压室由图3中的参考数字310确定。
当基材130离开模具工具110时，基材130直接移动进入由加压装置120形成的加压室310。装置120的壁可包括进口孔，基材130可穿过进口孔并且进入室310。进口孔可以是基材130可以穿过的任何合适的二维构型。进口孔可以或可以不符合基材130的轮廓。在某些实施中，进口孔可以比基材130的轮廓大很多，因此模具工具110的出口孔240可配置成形成围绕基材130的密封，该密封可作为涂覆室和加压室310之间的密封，尤其是当模具工具110的涂覆室中的压力水平大于加压室310中的压力水平时。
当涂覆过的基材130在加压室310中时，室310中的压力水平可以维持在一水平，该水平设计成阻止基材130和/或涂覆的涂层材料内的水分“蒸汽逃逸”，或设计成至少最小化“蒸汽逃逸”的水分的量。在某些应用中，与大气压力下水分的沸点相比，室310内的压力水平有效提高了包括在基材130和/或涂覆的涂层材料内的水分的沸点。因而，与基材130从模具工具110出来时的大气压力相比，使基材130和/或涂层材料经受较高的压力环境可减少和/或甚至消除水分“蒸汽逃逸”，水分“蒸汽逃逸”在涂层材料已经在模具工具110中在高温和高压下被涂覆到基材130之后可以以其他方式发生。因此，可采用加压装置120以扩大可在涂覆工艺中使用的基材产品和/或涂层材料的种类。例如，在加压装置120没有用于涂覆工艺时可能经历“蒸汽逃逸”的木材产品和/或基于木材的产品在加压装置120用于涂覆工艺时可以不经历“蒸汽逃逸”，或至少减少“蒸汽逃逸”。
加压室310可提供基材130的温度在受控的压力水平下冷却的时间，使得当基材130离开加压室310并经受大气压力时，基材130的温度可以已经冷却到不发生“蒸汽逃逸”的点，或使发生“蒸汽逃逸”的量最小。基材130的一部分在加压室310内的时间可称为“停留时间(dwell time)”。
在加压室310中发生的冷却的量可以基于一个或多个因素确定，因素包括加压室310的尺寸(如，基材130所穿过的室的长度)、室310内的温度、基材130在室310中的停留时间以及基材130穿过室310的速度。可以调节这些因素中的一个或多个以适合实际涂覆应用。例如，可以调节室310的长度和/或基材穿过的速率，使得当基材310经受受控的压力时在加压室310内可以发生期望的量的冷却。
对于某些示例性的涂覆应用，装置120的长度可以是约十二英寸至二十四4英寸(12-24英寸)，室310中的空气压力可以是约五至八十磅每平方英寸(5-80psi)，并且基材130穿过加压室310的速度可以是约十至二百英尺每分钟(10-200ft/min)。这些设置仅仅是说明性的。其他设置可在其他应用中使用。
基材130可以任何合适的方式被供入穿过模具工具110和加压装置120，方式包括例如‘086专利中描述的方式中的任一种。如图1所示，加压装置120可包括形成出口孔的出口板组件150，基材130最终通过出口孔离开加压装置120。出口板组件150的出口孔可形成允许加压室310中的压力被控制的围绕基材130的密封。在某些实施方式中，出口孔是基材130的二维轮廓。在某些实施方式中，出口板组件150配置成可移除地附接到加压装置120的壁并且从加压装置120的壁移除。因此，具有不同的轮廓出口孔的出口板组件150可以基于要被涂覆的基材130的轮廓被方便地换进和换出。
在某些实施方式中，出口板组件150可形成围绕基材130的可调节的密封，密封可以被调节以帮助控制加压室310中的压力水平。例如，密封可以被绷紧(tighten)以更紧贴在基材轮廓周围。较紧的密封可允许在加压室310中维持较高的压力水平。相反地，较松的密封可以帮助维持加压室310中的较低的压力水平。
可调节的出口密封可以任何合适的方式被提供。例如，具有出口孔的出口密封工具可被放置在出口板组件150和加压装置120的壁之间。出口密封工具可以包括允许出口密封工具基于施加于出口密封工具上的压力来改变形状的材料(如，橡胶)。例如，就置于出口板组件150和加压装置120的壁之间的出口密封工具而言，出口板组件150和壁可以被挤压在一起，例如通过使出口板组件150向壁拉紧，以使密封紧密。出口密封工具可以通过逐渐侵入(encroach)出口孔中并且从而形成围绕基材130的更紧的密封而对挤压作出回应。相反地，出口板组件150和壁可以被移动分开以使密封松弛。在其他实施方式中，出口密封工具可被放置在出口板组件150中包括的两个出口板之间，并附接到加压装置120的壁。两个出口板可以被挤压在一起和/或移动分开以分别使密封紧密和/或松弛。
在某些实施方式中，加压装置120可以包括用于对准将穿过由出口板组件150形成的出口孔的基材130的一个或多个对准机构160。对准机构160可配置成相对于出口孔竖直地或水平地对准基材130。图1和图3显示示例性的对准机构160，每个对准机构160包括定位在加压室310内的对准辊。辊的位置可以被调节以引导基材130穿过出口板150的出口孔。在某些实施方式中，对准辊可被调节成向内朝向以及向外远离加压室310中的基材130。调节可以任何合适的方式作出。在图1和图3中所示的例子中，每个对准机构160包括定位在加压室310外部的调节控制器(如，旋钮)。调节控制器可用于(如，***作者手动旋转)调节对准辊在加压室310内的位置。可调节的对准机构160尤其可以帮助把装置120配置成适应各种基材产品(如，装饰性的模塑)的各种弯曲度。
在某些实施方式中，加压装置120可包括允许快速通向和/或密封或开封加压室310的快速释放顶部。快速释放顶部还可以提供在加压装置120内部的方便的操作者通路。如图1所示，加压装置120可包括用于快速固定或移除加压装置120的顶部的快速释放机构170。示例性的快速释放机构170和快速释放顶部仅仅是说明性的。
图4和图5图示了加压装置120的透视图。图4图示了形成进口孔410的端板，基材130可以从模具工具110通过进口孔410进入加压室310。在图4的例子中，进口孔410配置成允许具有各种尺寸、形状和轮廓的基材310穿过进入加压室310。即，进口孔410的轮廓不为了特定的基材轮廓而被特别地设计。因此，在并非必须换出形成进口孔410的端板的情况下，各种基材310可以进入加压室310。如上描述，模具工具110的出口孔可配置成形成围绕基材310的密封，该密封可作为加压室310的密封。因而，进口孔410可比基材130的轮廓大很多。
图5图示了由出口板组件150形成的示例性的出口孔510。如所示，出口孔510可配置成符合特定的基材轮廓并形成围绕基材130的密封。
图6是示例性的加压装置120的部件的分解透视图。如图6所示，加压装置120可包括底板610、侧板620、端板630、顶板640、垫圈650、对准出口板660、出口密封工具670、出口板680、对准机构160和快速释放机构170。这些部件可以适合于形成图4和图5中所示的加压装置120的任何方式相互附接。部件可由任何合适的材料制造，材料包括金属、塑料、橡胶或其组合或次组合(sub-combination)。
图7图示了示例性的加压和涂覆***700，加压和涂覆***700包括在其中实施的模具工具110和加压装置120。***700可以包括相互附接的涂层材料储罐710、涂层挤出机720和模具工具110，使得涂层材料可以从储罐710行进到挤出机720以及行进到模具工具110，以便在基材130穿过模具工具110时涂覆到基材130。
***700还可以包括附接到储罐710和挤出机720的且配置成把涂层材料加热至流体态的加热器730。放置于储罐710内的涂层材料可被加热器730加热至允许涂层材料经过泵或通过重力流动至挤出机720的液化或流体温度状态。由于涂层材料现在是液体或流体态，所以它可通过涂层材料进料器250行进至在模具工具110内形成的涂覆室。在某些实施方式中，涂层材料可以环绕着模具工具110中的出口孔240的周边。一旦足够量的涂层材料聚集在涂覆室内并且沿着出口孔240的周边，那么当基材130穿过模具工具110时，涂层材料将易于被涂覆到基材130。
***700还可以包括进料器组件740，进料器组件740可配置成在操作期间供入待加工和涂覆的基材130。进料器组件740可以包括被配置成将基材130供入穿过模具工具110和加压装置120的任何合适的机构，包括压在基材130上并且配置成控制基材130穿过模具工具110和加压装置120的传送速率的机动皮带传动(motorized belt drive)。当基材130穿过模具工具110时，涂层材料以受控的方式或在模具工具110相对于基材表面所允许的公差范围内被直接涂覆到基材130的表面。
如上所述，当基材130离开模具工具110并进入加压装置120内的加压室310时，室310内的受控的压力会起到减少或消除水分蒸汽逃逸的作用。加压工具755(如，空气压缩机、空气软管和计量器)可以附接到加压装置120，并且用来向加压装置120提供空气和/或其他气体以产生和监测加压室310中受控的压力环境。在基材已经穿过模具工具110和加压装置120之后，出口组件760可接收基材130。
可以使用本文描述的加压和涂覆***、装置、方法和原理来涂覆的产品的例子包括但决不限于：用于居住和商业建筑的基底和油画外框、用于内部和外部应用的贴面、装饰性修整木工产品、画框表面、窗口遮盖物(如，遮帘和百叶窗)、金属贴面和修整机件(finish work)、厚木板(如4’×8’面板)以及壁板(如，金属和乙烯树脂壁板)。这些例子仅仅是说明性的并且不在任何意义上作为限制。其他产品可在其他实施方式和应用中被涂覆。
图8图示示例性的加压涂覆方法。虽然图8图示了根据一个实施方式的示例性的步骤，但其他实施方式可以删除、添加、重排和/或修改图8所示的步骤中的任一个。
在步骤810中，基材130被供入穿过模具工具110和加压装置120。步骤810可以上面描述的任何方式实施，包括使用进料器组件740来供入基材130。
在步骤820中，涂层材料被涂覆到基材130。步骤820可以上面描述的任何方式实施，包括预处理(如，加热)涂层材料、向模具工具110提供涂层材料以及在基材130被供入穿过模具工具110时把涂层材料涂覆到基材130。
在步骤830中，基材130在加压装置120的加压室310中被接收。步骤830可以上面描述的任何方式实施，包括从模具工具110直接接收基材130。
在步骤840中，控制加压室310内的基材130周围的压力。步骤840可以上面描述的任何方式实施，包括控制加压室310内的空气压力水平。压力可被设置成或维持在可以适合特定的实施方式和/或涂覆应用的压力水平。在某些应用中，压力水平被维持在模具工具110中的压力水平和大气压力之间的水平。如上面描述，加压室310内受控的压力可设置成减少或消除水分从基材130的“蒸汽逃逸”。
在步骤850中，接收来自加压室310的基材130。步骤850可以本文描述的任何方式实施，包括当基材130离开加压装置120时出口组件760接收基材130。
本文描述的加压***、方法和装置可以一方式在使用各种涂层材料和各种基材材料的各种涂覆工艺中采用，所述方式能消除或至少减少“蒸汽逃逸”和/或可以其他方式被基材中的挥发性材料引入的其他突发事件(flash event)。这样的挥发性材料的例子包括但不限于水分或在经受环境温度和/或环境压力突变时可以不期望地反应的任何其他材料。挥发物可以被天然地或合成地包括在基材材料中。作为一个例子，木材、塑料、金属以及其他材料中的水分当经受环境温度和/或环境压力突降时可被认为是挥发物。可采用本文描述的原理来消除或至少减少“蒸汽逃逸”或可以其他方式在这样的产品中发生的其他突发事件的数量。
挥发物还可以存在于或被引入涂层材料中。在涂覆工艺中可采用本文描述的原理来消除或至少减少“蒸汽逃逸”和/或可以其他方式被涂层材料中的挥发性材料引入的其他突发事件。因而，在涂覆工艺中可采用本文描述的原理来保护基材和/或涂层材料免于不期望的突发事件。
可采用本文描述的原理来保护通常不包括挥发性材料的材料。作为例子，某些塑料基材或涂层材料通常可以不包括水分，但制造工艺可能会不注意地把水分引入这样的塑料基材或涂层材料中。当采用本文描述的原理时，本文描述的原理可保护塑料基材或涂层材料免于经历由于包括在其中的未知水分引起的突发事件。因而，在许多涂覆工艺中可采用本文描述的原理来保护各种材料免于可以以其他方式被材料中的许多挥发物中的任一种引起的突发事件。
已经参考附图仅仅提出了前述描述，以便图示和描述示例性的实施方式。然而，明显的是可对其做出各种修改和改变，并且可以实施另外的实施方式，而不偏离在下文的权利要求中提出的本发明的范围。因而，上面描述和附图应以说明性的而非限制性的意义来理解。

Claims (20)

1.一种***，包括：
模具工具，其配置成把涂层材料涂覆到正在穿过所述模具工具的基材；以及
加压装置，其附接到所述模具工具，所述加压装置形成加压室；
其中所述加压装置配置成接收来自所述模具工具的所述基材并控制所述加压室中的所述基材周围的压力。
2.如权利要求1所述的***，其中所述模具工具形成涂覆室并配置成把所述涂层材料涂覆到在所述涂覆室中的所述基材的至少一个表面上。
3.如权利要求2所述的***，其中所述加压装置配置成把所述加压室中的所述压力维持在大气压力和所述涂覆室中的压力之间的水平。
4.如权利要求1所述的***，其中所述压力包括空气压力，并且所述加压装置配置成控制所述加压室中所述基材周围的所述空气压力。
5.如权利要求1所述的***，其中所述加压装置附接到所述模具工具，使得在所述加压装置和所述模具工具之间形成空气压力密封。
6.如权利要求1所述的***，其中所述加压装置包括形成出口孔的出口板组件，所述基材穿过所述出口孔离开所述加压室。
7.如权利要求6所述的***，其中所述出口孔形成所述基材的二维轮廓。
8.如权利要求6所述的***，其中所述出口板组件配置成形成围绕所述基材的可调节的密封。
9.如权利要求8所述的***，其中所述可调节的密封配置成围绕所述基材拉紧和松驰中的至少一个。
10.如权利要求6所述的***，其中所述加压装置包括至少一个可调节的对准机构，所述可调节的对准机构配置成将所述基材与所述出口孔对准。
11.如权利要求10所述的***，其中所述可调节的对准机构包括在所述加压室内的辊以及在所述加压室外的调节控制器，其中所述调节控制器配置成用来调节所述辊在所述加压室内的位置。
12.如权利要求1所述的***，还包括：
涂层材料储罐，其配置成容纳所述涂层材料；
加热器，其配置成把所述涂层材料加热到液化状态；以及
挤出机和涂层材料进料器，其配置成向所述模具工具提供所述液化的涂层材料以涂覆到所述基材。
13.如权利要求12所述的***，还包括进料器组件，其配置成将所述基材供入穿过所述模具工具和所述加压室。
14.如权利要求1所述的***，其中所述加压装置配置成将所述加压室中的压力维持在约五至八十磅每平方英寸(5-80psi)之间的水平。
15.如权利要求1所述的***，其中所述基材包括装饰性修整木工产品。
16.如权利要求1所述的***，其中所述基材包括木材产品和基于木材的产品中的一个。
17.一种***，包括：
模具工具，其形成涂覆室并配置成把涂层材料涂覆到正在穿过所述涂覆室的基材；以及
涂层材料储罐，其配置成容纳所述涂层材料；
加热器，其配置成加热所述涂层材料；
挤出机和涂层材料进料器，其配置成向所述模具工具提供所述涂层材料以涂覆到所述涂覆室中的所述基材。
加压装置，其附接到所述模具工具，所述加压装置形成加压室；以及
进料器组件，其配置成将所述基材供入穿过所述模具工具和所述加压室；
其中所述加压装置配置成从所述模具工具直接接收涂覆过的基材并且控制所述加压室中的所述涂覆过的基材周围的空气压力。
18.一种方法，包括：
将基材供入穿过模具工具和附接到所述模具工具的加压装置；
将涂层材料涂覆到所述模具工具中的所述基材的至少一个表面；
将来自所述模具工具的所述基材接收入所述加压装置中；并且
控制所述加压装置内的所述基材周围的压力。
19.如权利要求18所述的方法，其中所述加压装置形成加压室，并且其中所述控制所述基材周围的压力包括控制所述加压室中的空气压力。
20.如权利要求19所述的方法，其中所述模具工具形成涂覆室，并且其中所述控制所述空气压力包括把所述空气压力维持在大气压力和所述涂覆室内的压力之间的水平。
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