CN111283959A - 利用液相反应固化工艺制造具有复合层的真实材料制品的方法 - Google Patents

利用液相反应固化工艺制造具有复合层的真实材料制品的方法 Download PDF

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CN111283959A
CN111283959A CN201910860625.8A CN201910860625A CN111283959A CN 111283959 A CN111283959 A CN 111283959A CN 201910860625 A CN201910860625 A CN 201910860625A CN 111283959 A CN111283959 A CN 111283959A
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layer
real material
real
resin layer
plastic resin
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金槿河
崔源栽
崔钟守
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Intops Co Ltd
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Intops Co Ltd
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    • C09D123/00—Coating compositions based on homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Coating compositions based on derivatives of such polymers
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    • C09D123/28—Coating compositions based on homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Coating compositions based on derivatives of such polymers modified by chemical after-treatment by reaction with halogens or compounds containing halogen
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    • C09D175/00—Coating compositions based on polyureas or polyurethanes; Coating compositions based on derivatives of such polymers
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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Abstract

本发明的利用液相反应固化工艺制造具有复合层的真实材料制品的方法可以通过双重注塑工艺精密且美丽地制作真实材料制品，可以实现各种图案。真实材料层的下部涂覆有塑料树脂层，上部涂覆有聚脲(PUA)或聚氨酯(PUR)层。

Description

利用液相反应固化工艺制造具有复合层的真实材料制品的 方法
技术领域
本发明涉及一种利用液相反应固化工艺制造具有复合层的真实材料制品的方法。具体地，本发明涉及一种利用液相反应固化方法制造在真实材料的两面形成有复合层的真实材料制品的方法。
背景技术
作为汽车内部、外部装饰用、手机面板、洗衣机之类的电子设备的按钮或标志部分的装饰材料，例如，利用真实木材之类的内饰材料来提高产品的质感、触感等外观，并切断噪音、火焰、氧气等，从而保护内部结构。
韩国登记专利第10-0913811号公开了一种利用真实木片作为内饰材料的成型品制造方法。如图1所示，该专利在真实木片10‘的下部一次注塑出背面层20’，在上部二次注塑出表面层30‘。背面层20’和表面层30‘利用相同树脂，即热可塑性树脂，例如ABS(acrylonitrile butadiene styrene，丙烯腈·丁二烯·苯乙烯)树脂、丙烯酸树脂、聚碳酸酯树脂制造而成。
申请人的韩国公开专利第10-2018-0069404号公开了一种“真实木材的成型物制造方法”，即，将真实木材和塑料树脂一起嵌件成型后涂装真实木材的前面的工艺。涂装层防止真实木材的表面从外部受到损伤，并可以使得长期保持天然木材料感和光泽。
在所述专利中，作为形成如表面层和涂装层一样的涂覆层的二次工艺，例如，利用喷涂法和压缩成型法。喷涂法的情况，如图2a所示，属于利用喷涂法在下部形成有塑料材料的树脂层12’的真实木片10’的上部形成涂覆层14’的方法。一般，真实木片10‘的上面和实际木材一样大多情况下粗糙度粗糙，而喷涂法的缺点是，为了使得喷射顺畅进行，含有类似稀释剂的挥发物质，结果，即使光滑地形成了涂覆层，在之后的干燥过程中，挥发物质蒸发，如图所示，留下粗糙度高的涂覆层，所以需要执行平滑作业。
压缩成型法的情况，如图2b所示，虽然属于在下部形成有塑料材料的树脂层12’的真实木片10’的上部排出固化材料140‘的状态下通过按压未图示的模具来均匀地压缩材料140’而制造涂覆层的方法，但是不便之处在于，需要在涂覆后截断材料140‘溢出的边缘部142’。
发明内容
因此，本发明的目的在于，提供一种可以在真实材料层形成复合层的改善了的液相反应固化模具制造方法。
为了实现所述目的，本发明提供一种利用液相反应固化工艺制造具有复合层的真实材料制品的方法，其特征在于，同时执行以下步骤：(1)对真实材料进行剪切及加热成型，从而形成真实材料层；(2-1)将真实材料层安装于成型机的第一空腔，使得供给至第一空腔的塑料树脂固化，从而在真实材料层的第一面形成塑料树脂层；(2-2)将形成有塑料树脂层的所述真实材料层安装于成型机的第二空腔，向第二面供给液相树脂并使其固化，从而形成第二树脂层；(2-3)在执行(2-2)步骤时，向安装于成型机的第一空腔的又另一第二真实材料层供给塑料树脂并使其固化，从而在所述第二真实材料层的第一面形成塑料树脂层；据此，可以连续注塑出具有复合层的真实材料制品，所述复合层第一面形成有塑料树脂层，第二面形成有固化树脂层。
所述第二树脂层可以是聚氨酯(PUR)或聚脲(PUA)材料。
所述塑料树脂层可以是聚碳酸酯(polycarbonate,PC)、聚酰亚胺(polyimide,PI)、聚醚砜(polyethersulfone,PES)、聚芳酯(polyarylate,PAR)、聚萘二甲酸乙二醇酯(polyethylene naphthalate,PEN)、聚对苯二甲酸乙二醇酯(polyethyleneterephthalate,PET)、环烯烃共聚物(cycloolefin copolymer)、丙烯酸树脂、丙烯腈·丁二烯·苯乙烯(acrylonitrile butadiene styrene，ABS)、丙烯腈-苯乙烯-丙烯酸酯(acrylonitrile styrene acrylate，ASA)、聚对苯二甲酸丁二醇酯(polybutyleneterephthalate,PBT)或苯乙烯丙烯晴(styrene acrylonitrile，SAN)。
所述真实材料可以是包括木材、纤维、石头、人造革、塑料的碳纤维复合材料，类似玻璃纤维增强塑料的复合材料或金属板材。
为了提高与所述聚氨酯(PUR)或聚脲(PUA)材料的黏着力，在真实材料层的第二面进行等离子体预处理或以聚氨酯或氯化聚烯烃为主成分材料进行引物等预处理。
可以利用图案模具在塑料树脂层或第二树脂层赋予立体感或形成光泽所需的润泽层或赋予色彩。
另外，本发明提供一种利用以上方法制造的具有复合层的真实材料制品。
本发明在注塑成型工艺中通过调节模具的空间可以调节涂覆层的厚度，因此和材料的粗糙度无关，可以实现美丽的外观，并且通过在模具面进行光泽、哑光、图案等加工可以实现多种设计。
另外，本发明通过同时进行注塑模具作业来完成液相固化成型，因此工艺简单，收率高，质量提升，且可以减少成本，使得立体图案极大化。
附图说明
图1是现行技术的真实木材成型品的截面图。
图2a是用于说明现行技术中喷涂法的概念图。
图2b是用于说明现行技术中压缩成型法的概念图。
图3是示出本发明的利用液相反应固化工艺制造具有复合层的真实材料制品的工艺中的到制造真实材料层为止的工艺的流程图。
图4是示出本发明的利用液相反应固化工艺制造具有复合层的真实材料制品的工艺中的执行双重注塑的工艺流程图。
图5a至5d是示出利用成型机的平面图进行图4的工艺的作业方法图。
标号说明
10：真实材料层 12：塑料树脂层 20：上部层
100：移动板 102：固定板 104：第一喷头
108：第二喷头 110：第一空腔 210：第二空腔
具体实施方式
以下通过附图对本发明的部分实施例进行详细说明。
需注意的是，在对各附图的构成要素赋予参照标号时，针对相同的构成要素，尽管显示在不同的图中，但尽可能地使之具有相同的标号。另外，在对本实施例进行说明时，判断对相关公知构成或功能的具体说明可能会模糊本实施例的要旨时省略对其的详细说明。
就本发明的液相反应固化工艺而言，其特征在于，为了制造具有复合层的真实材料制品，在一个成型机中同时连续地执行一次及二次注塑(模具)工艺。现有技术中，使用层压法、喷涂法之类的涂装方法或者利用注塑工艺的情况，为了在真实材料形成复合层，反复执行详细的模具工艺，从而具有作业效率低、工艺繁杂、收率低的缺点。
另外，本发明的特征在于，针对真实材料同时进行成型工艺，从而以真实材料层为中心在第一面形成塑料树脂层的同时在第二面形成聚氨酯或聚脲层，由此迅速且精密地制造具有复合的制品。
本发明的利用液相反应固化工艺的具有复合层的真实材料制品经过图3及图4的工艺制造而成。
首先，按照最终产品的形状对木头之类的真实材料进行剪切(S10)。木头只是一个例子，真实材料不限于使用纤维、石头、人造革、类似碳纤维固化塑料(CFRP)的包括塑料的碳纤维复合材料，类似玻璃纤维增强塑料的复合材料或金属板材等。剪切优选利用数控机床进行激光剪切，但是耐热性较弱的材料或硬度高的金属的情况，省略激光剪切或者也可以利用切割刀片进行物理截断。
接下来，对剪切的真实材料进行加热成型(S12)。具体地，按照最终产品的形状对事先制造的模具进行预热，放置好真实材料后利用压力机进行热压缩。真实材料上孔隙较多的情况，使得丙烯酸树脂、SAN等透明的可塑性树脂溶液以及粉末含浸后，经过热成型过程，借助于热压缩去除孔隙，由此可阻止在后述的模具工艺产生气泡。因热导致液相或物性变化的真实材料的情况，省略热成型工艺，可以直接供给至后述的模具工艺。以下，在本说明书中将经过热成型工艺或供给至模具工艺之前的真实材料半成品称作“真实材料层”。
接着，针对图4的双重模具工艺参照示出成型机的平面图的图5a至图5d首先从结构层面进行说明。
本发明的用于实现液相反应固化方法的成型装置包括：移动板100；移动模具100A，其与移动板100形成为一体；固定板102；固定模具102A，其与固定板102形成为一体且与移动模具100A面对面延长；旋转模具200，其设置于移动模具100A和固定模具200A之间。旋转模具200由形成真实材料110的背面的两个相同形状的分割模具200A、200B构成。
为了贯通固定板102，在其侧面设置有作为喷嘴的第一喷头104。第一喷头104的内部端与第一空腔110连通并与第一通道106连接，第一通道106贯通固定模具102A的直径短且纤细。第一喷头104的外部端和图中未示出的螺旋装置连接，同样未示出的料斗所流出的溶液通过螺旋被挤压，经由第一喷头104和第一通道106后被供给至第一空腔110。溶液用于形成塑料树脂，可以使用聚碳酸酯(polycarbonate,PC)、聚酰亚胺(polyimide,PI)、聚醚砜(polyethersulfone,PES)、聚芳酯(polyarylate,PAR)、聚萘二甲酸乙二醇酯(polyethylene naphthalate,PEN)、聚对苯二甲酸乙二醇酯(polyethyleneterephthalate,PET)、环烯烃共聚物(cycloolefin copolymer)、丙烯酸树脂、丙烯腈·丁二烯·苯乙烯(acrylonitri le butadiene styrene，ABS)、丙烯腈-苯乙烯-丙烯酸酯(acrylonitri le styrene acrylate，ASA)、聚对苯二甲酸丁二醇酯(polybutyleneterephthalate,PBT)或苯乙烯丙烯晴(styrene acrylonitri le，SAN)等任意一个。
小直径的第二通道112设置于从移动模具100A的侧面连通到第二空腔210的通道，在和第二通道112连通的侧面设置有作为喷嘴的第二喷头108。分别从图中未示出的异氰酸酯储槽和多元醇储槽向第二喷头108供给溶液，混合的溶液形成聚氨酯(PUR)溶液，聚氨酯溶液被供给至第二通道112。代替多元醇，也可以供给胺(amine)、聚脲(PUA)。PUR的隔热、防水性能优秀，容易加工和施工，和基材的黏着性优秀。PUA的耐热性以及和基材的黏着性优秀，固化迅速，时间为几秒，硬度和弹性好。
接下来，作为作业方法，在上述的成型机中，将经过图3的工艺的真实材料层10安装于第一空腔110内后，通过第一喷头104和第一通道106供给塑料树脂，从而在真实材料层10的下面(图5a的100的左侧)形成塑料树脂层12。虽然图5a中没有具体示出，但是第一通道106以在与第一空腔110面对的部分迂回的形式形成通道，树脂供给至真实材料层10的背面。第二空腔210为没有安装任何东西的待机状态。
接着，如图5b所示，利用通过使得移动板100和移动模具100A向左侧进行线性移动而确保的空间，向示出旋转模具200的箭头方向旋转180度后，从未示出的供给机获得其他新的真实材料层10‘的传递后安装于第一空腔110。此时，附着有塑料树脂层12的真实材料层10的上面在第二空腔210露出。在该状态下，通过第二喷头108供给PUA或PUR并通过第一喷头104供给塑料树脂，由此如图5c所示，在真实材料层10的上面形成上部层20，在新的真实材料层10’的下部面形成塑料树脂层12‘。并且，如图5d所示，在使得移动模具100A和旋转模具200向左侧进行线性移动后，取出形成有复合层的真实材料层10，由此完成利用液相反应固化工艺的真实材料制品。新的真实材料层10’回归至图5b的工艺，接着重新反复接受新的真实材料层的供给的作业，由此通过本发明的成型工艺可以在一个成型机中自动连续地制造真实材料制品。
在本发明的工艺中，第一喷头104使得热可塑性树脂溶解后供给，因此利用200度以上的高温进行加热，第二喷头108在40～90度内以液态物质状态供给。液态物质供给至真实材料层10和空腔210之间，填充空余空间后固化，因此可以利用迅速的液相反应工艺的优点。此外，可以通过变化模具和空腔的形状而精密地决定复合层的形状和大小，因此，可以一举消除喷涂法或压缩成型法的缺点。
参照图4对上述在成型机中的双重模具工艺的作业流程进行说明。
首先，将真实材料层10安装于成型机(S14)，通过一次注塑工艺在真实材料层10的下部面形成塑料树脂层(S15)。获得新的真实材料层10‘的传递后安装于成型机(S20)，通过二次注塑工艺在真实材料层10的上部面形成PUA或PUR层20(S16)，同时通过一次注塑工艺在真实材料层10’的下部面形成塑料树脂层(S22)。形成有复合层的真实材料层10完成为真实材料制品后分离(S30)，新的真实材料层10‘成为待进行二次注塑工艺状态，其他新的真实材料层被供给而成为待进行一次注塑工艺状态。
在本发明中，形成于真实材料层10的上面的PUA或PUR层耐久性优秀，对温度和压力的变化不敏感，通过光泽或哑光处理可以赋予真实材料的自然性和美感，在这一点来说有利。
如此，本发明适用针对真实材料同时进行成型工艺，由此以真实材料层10为中心在第一面形成塑料树脂层2的同时在第二面形成聚氨酯或聚脲层20，从而可以迅速且精密地制造具有复合层的制品。
针对本发明的成型工艺可以进行如下变形。
以上以通常的模具为前提，但是利用图案模具可以赋予立体感或形成光泽所需的润泽层或可以赋予色彩。
此外，为了使得PUA及PUR液相与真实材料层10很好地附着，在图3的真实材料热成型工艺(S12)后，利用等离子体或引物可以在真实材料层10的上面进行预处理，或者同时进行等离子体和引物预处理。优选地，引物材料以聚氨酯或氯化聚烯烃为主成分材料，并追加有丙烯酸成分。用引物涂覆木头的上面的情况，附着力为30N以上，涂覆碳的上面的情况为25N以上，确认到附着力提高。
以上以本发明的优选实施例为例进行了说明，但这些例子不限制本发明的权利范围，可以对本发明进行多种变更，这些也均在本发明的权利范围内，本发明的权利范围通过以下所附的权利要求书得到确定。

Claims (7)

1.一种利用液相反应固化工艺制造具有复合层的真实材料制品的方法，其特征在于，同时执行以下步骤：
(1)对真实材料进行剪切及加热成型，从而形成真实材料层；
(2-1)将真实材料层安装于成型机的第一空腔，使得供给至第一空腔的塑料树脂固化，从而在真实材料层的第一面形成塑料树脂层；
(2-2)将形成有塑料树脂层的所述真实材料层安装于成型机的第二空腔，向第二面供给液相树脂并使其固化，从而形成第二树脂层；
(2-3)在执行(2-2)步骤时，向安装于成型机的第一空腔的又另一第二真实材料层供给塑料树脂并使其固化，从而在所述第二真实材料层的第一面形成塑料树脂层；
据此，可以连续注塑出具有复合层的真实材料制品，所述复合层第一面形成有塑料树脂层，第二面形成有固化树脂层。
2.根据权利要求1所述的方法，其特征在于，
所述第二树脂层为聚氨酯(PUR)或聚脲(PUA)材料。
3.根据权利要求2所述的方法，其特征在于，
所述塑料树脂层为聚碳酸酯(PC)、聚酰亚胺(PI)、聚醚砜(PES)、聚芳酯(PAR)、聚萘二甲酸乙二醇酯(PEN)、聚对苯二甲酸乙二醇酯(PET)、环烯烃共聚物、丙烯酸树脂、丙烯腈·丁二烯·苯乙烯(ABS)、丙烯腈-苯乙烯-丙烯酸酯(ASA)、聚对苯二甲酸丁二醇酯(PBT)或苯乙烯丙烯晴(SAN)。
4.根据权利要求2所述的方法，其特征在于，
所述真实材料为包括木材、纤维、石头、人造革、塑料的碳纤维复合材料，包括玻璃纤维增强塑料的复合材料或金属板材。
5.根据权利要求2所述的方法，其特征在于，
为了提高与所述聚氨酯(PUR)或聚脲(PUA)材料的黏着力，在真实材料层的第二面进行等离子体预处理或以聚氨酯或氯化聚烯烃为主成分材料进行引物预处理或同时进行等离子体及引物预处理。
6.根据权利要求4所述的方法，其特征在于，
利用图案模具在塑料树脂层或第二树脂层赋予立体感或形成光泽所需的润泽层或赋予色彩。
7.一种利用根据权利要求1至6中任意一项所述的方法制造的具有复合层的真实材料制品。
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