CN1119236C - 螺旋成形产品及制造方法 - Google Patents

螺旋成形产品及制造方法 Download PDF

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Publication number
CN1119236C
CN1119236C CN98810192A CN98810192A CN1119236C CN 1119236 C CN1119236 C CN 1119236C CN 98810192 A CN98810192 A CN 98810192A CN 98810192 A CN98810192 A CN 98810192A CN 1119236 C CN1119236 C CN 1119236C
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China
Prior art keywords
thermoplastic foam
foam member
thermoplastic
microscler
shape
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Expired - Fee Related
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CN98810192A
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English (en)
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CN1275945A (zh
Inventor
兰德尔·亨德森
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Nomaco Inc
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Nomaco Inc
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    • 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
    • B29C53/00—Shaping by bending, folding, twisting, straightening or flattening; Apparatus therefor
    • 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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/09—Articles with cross-sections having partially or fully enclosed cavities, e.g. pipes or channels
    • B29C48/11—Articles with cross-sections having partially or fully enclosed cavities, e.g. pipes or channels comprising two or more partially or fully enclosed cavities, e.g. honeycomb-shaped
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C53/00—Shaping by bending, folding, twisting, straightening or flattening; Apparatus therefor
    • B29C53/56—Winding and joining, e.g. winding spirally
    • B29C53/58—Winding and joining, e.g. winding spirally helically
    • B29C53/60—Winding and joining, e.g. winding spirally helically using internal forming surfaces, e.g. mandrels
    • B29C53/607—Winding and joining, e.g. winding spirally helically using internal forming surfaces, e.g. mandrels having driving means for advancing the wound articles, e.g. belts, rolls
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    • B29C53/56—Winding and joining, e.g. winding spirally
    • B29C53/58—Winding and joining, e.g. winding spirally helically
    • B29C53/78—Winding and joining, e.g. winding spirally helically using profiled sheets or strips
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    • B29C66/4322—Joining a relatively small portion of the surface of said articles for making tubular articles or closed loops, e.g. by joining several sheets ; for making hollow articles or hollow preforms by joining a single sheet to itself
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
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    • 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
    • B29C66/739—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 material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392—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 material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
    • B29C66/73921—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 material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic characterised by the materials of both parts being thermoplastics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
    • B29C66/834—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools moving with the parts to be joined
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Abstract

通过缠绕和熔接具有需要尺寸和形状的热塑性泡沫型材(22)，可以容易地制成任意需要直径的中空热塑性泡沫管。采用热塑性泡沫挤压机生产具有需要横截面形状的型材(22)，将型材送至旋转支承构件(30)，以便缠绕在旋转支承构件上，并在螺旋缠绕时粘合型材(22)的抵接边缘。采用这种独特的螺旋成形的方法，可以连续地形成中空热塑性泡沫圆管(28)，其长度可按需要控制。另外，采用具有需要直径的旋转支承构件可形成需要的直径，挤压机形成的型材厚度控制管的壁厚。

Description

螺旋成形产品及制造方法
本发明涉及热塑性泡沫产品及制造方法，更具体来说涉及通过连续形成基本呈圆筒形形状来制造的热塑性泡沫产品。
近数十年来，对使用热塑性泡沫材料成形和构制产品，人们已付出大量的努力，并越来越引起人们的关注。这种产品一般是通过泡沫挤压或模制成形的。但是，不管使用什么方法，对能够以有竞争力的价格有效生产的产品的尺寸和形状存在生产局限性。
使用挤压法生产的这种产品的一个实例是用热塑性泡沫材料制造长形中空圆管。这种管使用在种类繁多的产品中，最典型的是用于流体管或导管的绝热。
虽然用于成形热塑性泡沫圆管的挤压制法近年来已发展成一种极为有效的生产***，但是，在传统的设备上不能生产大于大约7英寸的管径。即使大直径热塑性泡沫材料管存在相当大的市场，使用传统的挤压设备却不能满足这种需求。大直径泡沫管要求厂商投资购置极为昂贵的制造设备，才能满足使用目前技术的要求。
鉴于制造公司必须进行重大投资来购置设备，才能满足大直径圆管的工业需要，满足这种要求生产的产品，与较小直径热塑性管的传统价格相比较，是极为昂贵的。但是，尽管对这种产品有需求，并且有对具有竞争力价格的工业需要，现有技术一直不能提供以低成分、具有竞争力价格的方式来生产大直径圆管的制造方法。
除了对大直径中空圆管的工业需要以外，也存在许多种厚度的大型热塑性泡沫板材的需求。一般来说，用来成形热塑性泡沫产品的传统挤压设备不能生产厚度约为1/2”的宽度大于大约12”的聚合物泡沫板材。因此，对大宽度泡沫塑料板的要求是不能由传统的制造厂商来满足的。为了满足对这种产品的需要，必须购置极为昂贵的、专为客户设计的设备，从而使所生产的大宽度泡沫板材较为昂贵。另外，对这种投资的资金回报不高。
虽然拥有这种昂贵设备的专业厂商能够生产大宽度形状的热塑性泡沫板材，但是，这些厂商仍在所能生产的单块板材的厚度上受到限制。一般来说，现有技术的板材挤压机所能生产的板材的最大厚度为1/2”。
因此，需要厚于1/2”的最终产品的客户，需要采用多个切至尺寸的板，将其彼此整体粘合以达到最终产品的需要厚度。因此，引起附加的制造和搬运成本，用这种专门方法生产的最终产品的成本显著提高。
为了生产厚度大于1/2”的板材，需要在附属过程中将多个片叠置粘合起来，每个过程使型材增厚1/2”。这种叠层步骤显著提高了制造过程的复杂性，也使总的报废率提高。
在为了能够生产厚度大于1/2”的板材的努力中，贮料装置(accumulator)已经构制出来，并用于挤压机。通过采用挤压机/贮料装置组合，泡沫塑料直接从挤压机送至贮料装置，直至贮料装置被填满。然后，使用一活塞将贮存的塑料压出贮料装置。使用这种***，可以制成厚达2”的板材。但是，这种方法效率不高，这是由于它必须断续运转，不能连续操作。另外，由于断续的停机/启动过程也提高了废品率。
对这些***尽管需要改进制造技术，但是，一直未能研制出可以降低成本的有效的现有技术***。
因此，本发明的主要目的是提供一种用于制造大直径泡沫管和泡沫塑料板材的方法，这种制造方法简单、高效、成本相对较低。
本发明的另一个目的是提供一种新颖的制造方法，它具有上述特征，能够以成本极低的方式生产大直径中空圆管和大型泡沫板材。
本发明的另一个目的是提供一种新颖的制造方法，它具有上述特征，能够实现使用最少的人力和达到最高的生产率。
其它的和更为具体的目的，一部分是显而易见的，一部分将在下文中阐明。
采用本发明可以消除现有技术中的所有难点和缺陷，容易地生产任何直径的中空热塑性泡沫管，以及任何需要宽度和厚度的大型热塑性泡沫材料的片或板。在本发明中，可以不再需要以前为满足这些产品的工业需要所要求的复杂、昂贵的设备，可以使用易于采用的独特的制造方法。
按照本发明，采用一热塑性泡沫挤压***生产具有任何横截面形状或构成的型材，将型材送向一个旋转的圆筒形套筒。当泡沫型材沿圆周缠绕在旋转套筒上时，型材的抵接的边缘在螺旋形成形、制造操作中连续地彼此熔接。在其推荐实施例中，长形的挤压的热塑性型材以任何需要的角度送向旋转套筒，在喂入的型材的侧缘粘接于以基本连续的、螺旋成形方式缠绕的相邻型材侧缘时，使型材连续地、纵向地沿套筒长度前进。
采用上述独特的螺旋成形方法，可以连续地形成中空热塑性泡沫圆管，其长度可根据用户的需要加以控制。另外，采用具有产品所需内径的旋转套筒，可以形成任何需要的直径。管的厚度和外径可由挤压设备形成的型材的厚度来控制。
从上面的公开可以看出，可以实现一种高效率、低制造成本的方法，该方法可以生产热塑性泡沫材料形成的中空圆管，这种圆管可具有任何需要的壁厚和任何需要的直径。另外，通过以任何需要的长度切割形成的长管，可以生产客户需要的精确规格的产品。
除了提供具有客户需要的任何直径、壁厚和长度的长形中空泡沫塑料圆管以外，本发明的方法也可以生产具有客户需要的任何横截面形状、构造或孔型的中空圆管构件。本专业中公知，膨胀泡沫塑料挤压，作为成形工艺的一部分，可以形成任何需要的横截面形状、总体结构、孔型等。因此，通常可采用这些公知的成形技术与本发明的螺旋成形法结合，可以形成具有特别需要的类型或结构的圆管。按照这种方式，采用本发明可以比目前制造技术具有更高的灵活性和产品设计性能。
本发明的独特制造方法的另一特征是能够生产具有任何需要的壁厚、直径及总体结构的中空圆管，以及提供具有整体彼此粘合的两个或更多层的上述中空圆管。采用传统的技术，例如复合挤压、十字头挤压或在线粘合或熔接等，一层或多层附加材料可以粘贴在来自挤压设备的泡沫塑料的最初挤压层上。
根据需要，当将附加材料层粘贴在底层或型材上后，将多层型材送向本发明的螺旋成形制造设备。按照这种方式，可以按照需要的直径和壁厚制成客户寻求的精确的多层中空圆管构件。采用上述技术，可以按照显著提高的速率和生产能力制造以前传统公知制造技术所不能生产的产品。
除了提供上述独特结构的中空圆管以外，本发明的螺旋成形法也可提供任何需要的热塑性材料的基本平的片或板。已经发现，按照上述方式最初形成圆管，然后纵向切割或剖开管壁，螺旋成形的材料可以打开，形成热塑性泡沫材料的基本平的片或板。
采用这种制造技术可以形成具有任何厚度或构造的大宽度热塑性泡沫片或板，无需采用生产类似产品结构所需要的现有技术的昂贵的多步操作，或采用挤压机和贮料装置。另外，本发明可以制造按照客户需要的任何构造或类型形成的热塑性材料的平片或板。除了上述特征以外，本发明也可以制成易于生产、相对来说低成本的热塑性泡沫片或板材，其具有多层粘合在一起的不同材料层，以形成客户需要的任何形成或结构。
如上所述，本发明可以在一个单一的步骤中制成客户寻求的任何需要的规格的片或板材。因此，本发明引起整个片或板材制造业的革命，使用传统技术就可以制成最终产品，因此，显著降低了生产任何需要产品的成本。
从上面公开的内容可以看出，本发明能够按照经济、简单的方式，无需采用昂贵的、专门设计的设备就可以制成任何需要直径和壁厚的热塑性泡沫中空圆管，以及任何需要厚度、结构或外观的基本平的热塑性泡沫材料片或板。另外，减少了废料，并且可以根据客户需要，以任何颜色、尺寸或产品规格生产较小批量的产品。由于可以小批量生产，因而可以消除大量库存，显著降低成本。
为了更充分理解本发明的性质和目的，应该对照以下附图阅读下面的详细说明。
图1是在生产按照本发明的螺旋成形圆管时采用的制造设备的立体图；
图2是图1所示设备的一部分的放大立体图，其中表示用于形成本发明的中空管件采用的粘合操作；
图3是在图2所示设备中采用的粘合成形头部的推荐实施例的立体图；
图4是在成形本发明的中空管中采用的旋转心轴组件的分解立体图；
图5是完全组装的图4所示旋转心轴组件的立体图；
图6是图5的旋转心轴组件在其上形成中空管的过程中的立体图；
图7是在开缝以形成一个基本平的平板的过程中按照本发明形成的中空圆管的立体图；
图7A是一个辊系的立体图；
图8是按照本发明形成的基本平的热塑性泡沫板的立体图；
图9的立体图示意地表示按照本发明的方法的中空圆管的形成，其中在形成圆管之前第二材料层贴在挤压的泡沫层上；
图10的立体图放大地表示上面贴有第二层而形成的泡沫塑料板；
图11的立体图示意表示采用本发明形成双层中空圆管；以及
图12是挤压热塑性泡沫轮廓的14个不同形状的横剖图。
现在参阅图1-12及下面的详细说明可以更好地理解制造设备的结构、本发明的方法和本发明可制成的独特结构的产品。但是，从详细说明可以知道，对制造设备，方法的步骤和得到的产品可以进行各种改变而并不超出本发明的范围。因此，本说明书及图1-12公开的内容只是本发明的实例而并不是对本发明的限定。
在图1中完全地示出本发明的产品成形***20的推荐实施例。在该实施例中，产品成形***20包括一个挤压机21，它基本具有传统结构，用于生产具有侧缘25和26的任何需要形状的热塑性泡沫型材22。为了将热塑性泡沫型材22从挤压机21连续拉出并将其送至制管机24，采用了拉出器23。
在使用本发明时，可以使用任何热塑性材料形成型材22。但是，推荐的热塑性材料从下述组选择一种或多种：聚苯乙烯、聚烯烃、聚乙烯、聚丁烯(polybutanes)、聚氨酯、热塑性高弹体、热塑性聚酯、热塑性聚氨酯、聚酯、乙烯丙烯酸类共聚物、乙烯-乙酸乙烯酯共聚物、乙烯-丙烯酸甲酯共聚物、乙烯-丙烯酸丁酯共聚物、离聚物、聚丙烯及聚丙烯共聚物。
按照本发明，如图1，2，4和5所示，制管机24构制得可在连续转动的心轴30上接受热塑性泡沫型材22，使型材22缠绕在制管机24的旋转心轴30上，以并排抵接的关系连续形成许多螺旋缠绕匝27。按照这种方式，连续喂入的热塑性泡沫型材22基本呈螺旋形自动围绕心轴30转动，使喂入的型材22的侧缘25与前面缠绕匝27的侧缘26抵接。在接合点使抵接的侧缘25和26彼此粘合，形成基本圆筒形的中空管28。为了形成型材22的侧缘25与匝27的侧缘26的整体粘合，采用了粘接或熔接头部31。如果需要，粘接/熔接头部31可以包括多种交错的结构，以便实现侧缘25与侧缘26的需要的、牢固的相互粘合。在推荐实施例中，如图2和3所示，粘接/熔接头部采用了加热空气。
在该推荐实施例中，粘接/熔接头部31用导热材料构制成一个中空壳体，该壳体包括侧表面32和33、顶表面34和边缘35。通过在顶表面34上形成的入口36向头部31供应加热空气，从而将头部31的表面32和33的温度提高到使型材22和与头部31接触的匝27的侧缘温度升至其熔点的水平。另外，在推荐实施例中，头部31也包括在边缘35上形成的孔37，从而将热空气连续送到侧缘25和26，保证达到熔化温度，使侧缘25和26可靠地彼此熔接或粘接起来。
如图2所示，粘接/熔接头部31设置在喂入的型材22的侧缘25与前面螺旋缠绕的匝27的侧缘26接触的接合区上。使粘接/熔接头部31同时接触上述型材22的侧缘25和侧缘26，将表面温度提高到其熔点，从而使喂入的型材22直接与先缠绕的螺旋匝27的侧缘26接触，使表面密切彼此粘合。
在推荐的结构中，如图1和2所示，制管机24包括一个热空气发生器28，它直接连接于粘接/熔接头部31，以便向粘接/熔接头部31供应加热空气。虽然这种粘合操作中推荐使用加热空气，但是，也可以使用其它的粘接装置而并不超出本发明的范围。一种替代方案是使用加热的粘合剂，直接涂布在侧缘上。
制管机24最好装有当型材22接触旋转心轴30时接收型材并将型材22引导到心轴30上以形成匝27的装置。在图2所示的实施例中，采用多个导辊40，它们有不同的直径，使型材22处于相对于心轴30的需要位置，从而使型材22以形成匝27的需要角度送至旋转角心轴30。在图4和5所示制管机24的实施例中，采用精确弯曲的凸轮斜面41来接收喂入的热塑性型材22，并将型材22以形成匝27所需角度引到旋转心轴30上。
现在参阅图1，2和4-6及下面的详细描述，可以更好地理解制管机24的推荐实施例的结构和操作。在该推荐实施例中，制管机24包括支承壳体45，其内装有旋转的圆筒形套筒46，该套筒连续绕其中心轴线转动。另外，如图4所示，心轴30整体地连接于安装板47，而凸轮斜面41整体地连接于安装板48。为了提供心轴30相对于静止的凸轮斜面41的需要的连续转动，安装板47牢固安装在旋转的圆筒形套筒46上。另外，安装板48牢固地固定在壳体45上，从而在静止位置上将凸轮斜面41牢固地装在壳体45上，而心轴30则由于套筒46的连续转动而绕其中心轴线连续转动。
制管机24最好也装有一个支承框架50，其与旋转心轴30和支承壳体45配合工作。虽然支承框架50可以构制在多种不同的实施例中，但是，如附图所示，支承框架50的目的是当管28成形时为接收中空圆管28而被定位，并且在管28成形及从壳体45轴向延伸时为固定管28提供任何需要的支承作用。
虽然在制管机24形成管28时可采用多种不同的结构来保证中空圆管28的连续的、导向的、支承控制，但是装有支承框架50的推荐构件包括多个辊51，它们为适应管28的需要直径而专门构制成所需直径或可以调节。在推荐的结构中，辊51安装在框架50上，经过定位以便在管28形成并从壳体45轴向向外延伸时接触管28的外表面。通过提供支承辊，管28的连续转动及其从壳体45离开的轴向、纵向运动可以容易地被适应。
采用本发明，只要改变心轴30的直径就可以按照任何需要的直径来形成中空圆管28。将心轴30的外径构制得基本相当于管28的所需内径，从而精确实现管28的所需内径。因此，可以快速、方便地形成大直径中空圆管，无需使用昂贵、复杂、专门设计的制造设备。
除了采用不同直径的心轴以得到需要内径的管尺寸外，管28的厚度和外径是通过形成型材22的需要的尺寸和厚度来控制的。显然，作为挤压机21的挤压工艺的一部分，形成需要厚度的型材22就可以得到管28的需要壁厚。另外，下文将详细讲到，为了得到专门构制的管形状，挤压机21也可生产不同的结构和横截面形状。
除了生产具有任意需要的直径和壁厚的中空圆管以外，本发明也生产具有任何需要长度的中空圆管。如上所述，型材22由制管机24连续接受，制管机将喂入的型材22粘接于构成管28的前面接受并粘接的匝27的端部。因此，中空圆管28从支承壳体45连续地轴向前进，使形成的中空圆管可连续地增加长度直至被切断。这样可以容易地适应需要的管长度并有效地降低成本。
在图1中表示将中空圆管28切成需要长度的一个实施例。在该实施例中，切刀组件54有一刀片壳体55，在该壳体内装有连续转动的环形刀片56。最后，在该实施例中，刀片壳体55装在支柱57上，支柱57分别装在框架组件50的相对两侧。
在采用上述切管***的实施例中，当已经形成需要长度的管28时，刀片壳体55沿支柱57向上运行，使刀片56至少接触管28的下部。由于管28绕其中心轴线连续转动，中空圆管28接触刀片56的部分改变，从而使刀片56可以有效地整体切割管28，得到需要的长度。如图1所示，当得到所需长度时，它就可以在一输送***上送至任何需要的部位，使下一段中空圆管能够以相同的方式形成和切断。
如果需要的话，制管机24的另一个构件是对准辊60，如图6所示。如果采用的话，对准辊60直接与型材22牢固粘接于前一个缠绕匝27的位置相关地安装在支承壳体45上。对准辊60最好具有大于型材22宽度的总长度，采用这种对准辊就可以保证喂入的型材22以基本连续、光滑、平整的形状粘接于前一缠绕的匝27。这样，管28的外表面就可保持基本连续、光滑的与其整体形成的外表面。
如上所述，本发明的产品成形***20能有效生产最终具有任何需要的直径和壁厚的中空圆管28，无需使用昂贵的专门设计的制造设备。因此，成形大直径圆管取得了显著的进展。
除了在生产大直径中空泡沫管中的上述显著的进展和独特的发现以外，本发明也可以同样有效地生产大宽度的板或最后其有需要厚度的热塑性泡沫材料板。如图7所示，通过采用切刀装置65可从用成形的中空圆管方便地制成热塑性泡沫材料的基本平的板。
为了制成热塑性泡沫材料的基本平的板70，带有刀片66的切刀装置65基本以传统的方式安装和支承，以便纵向切过中空圆管28的管壁。当管28按照图7所示的方式纵向切割时，热塑性材料成形管28可以向外铺展，形成热塑性材料的基本平的片/板70。如果管28的长度不相应于片/板70所需要的长度，那么，只要将板70切至需要的长度以制成图8所示的板70。
从前面的描述可知，带有需要宽度的片/板70只要通过下述方式就可以制成：形成带有直径或圆周的中空圆管28，当将管28纵向剖开，形成片/板70，从而可以产生需要的宽度。另外，通过形成带有精确的所需厚度的型材22，就可以容易地制成任何所需厚度的板70。因此，采用本发明可只在一个生产步骤中制成带有任何宽度和厚度的片/板70，从而无需使用昂贵的、专门设计的制造设备，也无需使用为构制厚度大于1/2”的产品所需的许多重复的步骤。
从中空圆管28向基本平的板70的过渡或转换取决于在形成管28的过程中型材22的温度，以及当管28被纵向切割时塑料的温度。在推荐的操作中，使用加热的型材22形成圆管28，管28被切割，同时热塑性泡沫材料保持来自挤压过程的足够的热量。这样，板70自动形成或只要将板70以一个平的形状放置，并使板70以该形状冷却，从而容易地形成。
如果需要，可以采用图7A所示的辊***，如该图所示，辊80和81安装在一个壳体82中，并与驱动装置(未画出)相连接，该驱动装置以相反的方向连接于转动的驱动辊80和81。在推荐的结构中，辊80和81被旋转地驱动，使板70被辊80和81接受，并由于辊的转动在辊间自动前进。另外，在被绕辊80包缠后，借助带有支承台83的辊80，板70从辊80和81前进。
由于板是从圆管形成的，板70具有残留的弯曲形状，在这种情形中，可以采用图13所示的辊***，以便消除残余的弯曲。在辊70和81输送片/板70，使片/板70包绕辊，并从辊80出现在台83上，绕辊80板70的弯曲包绕抵消上述残余弯曲，从而可以消除片/板70的残余弯曲。采用上述辊***，片/板70中的任何残余弯曲可快速、容易地消除，以精确的需要的平的形状生产带有任何需要尺寸的片/板70。
在另一种生产情形中，即，使用加热的型材22形成管28，但是在切割前使其冷却，或者，在形成管28以前，型材22已经冷却，在管28已被纵向开缝后，一些残余弯曲仍旧存在。但是，在任何这样的情形中，只是将弯曲的片/板放在一个加热室中，使片/板形成基本平的形状。当片/板70已形成基本平整的形状时，片/板70在冷却后保持平的形状。
采用一般称为热成形法的方法，可以将片/板70形成任何需要的横截面形状。因此，如果需要，板70可以形成任何需要的形状如矩形，并放入加热室中。当充分加热后，将热塑性泡沫材料从加热室取出，使其以新形成的形状冷却。当冷却后，热塑性材料保持新的形状，直至以新的形状再热及放置。
为了制成能够满足用户需要的特殊条件的最终产品，许多泡沫产品形成有多个单独的不同的层。这种产品的实例包括：带利于耐用度或气候保护的外套叠层的中空圆管；具有纵向长缝以及在安装后用压敏粘合剂封闭长缝的泡沫管；带有利于提高温度保护或潮汽保护的内套叠层的泡沫管；带有专门粘合剂和/或保护衬层的泡沫片；具有不同颜色叠层的泡沫片或型材；以及为了改善结构性能用不同材料如线丝共同挤压成的泡沫管。
虽然现有的传统生产技术能够有效地生产具有多个层的泡沫型材和板以实现上述目的，但是，生产大直径管状类似产品成本极高。同样，用热塑性材料生产多层大型板材也是极难、成本很高的。但是，采用本发明就可以克服上述现有技术的难点和缺陷，并且可以得到一种竞争能力强的、成本低的、精致的生产***来生产多层中空圆管和片或板，其具有平的形状或任何需要的形状或结构。
图9示意地表示向型材22施加第二层的一种方法。在这个实施例中，虽然没有画出，但是管28是使用上述制管机24生产的。在这个实施例的方法中，第二层72借助粘合装置73固定在热塑性泡沫型材22上。如图所示，粘合剂涂布头74按照与第二层72共同工作方式设置，当层72从层辊75拉出时将粘合剂73涂布在它的一个表面上。
当粘合装置73涂布在层72的一个表面上时，载有粘合剂的层直接施加在型材72的一个表面上，牢固地将层72粘贴在型材72上。本专业技术人员懂得，将第二层72贴在型材22上可以采用多种不同的构制方法和层。图9所示的方法仅是用于说明的目的，而并非对本发明的限定，这是由于可以使用许多不同的方法而并不超出本发明的范围。
当层72固定在型材22上后，双层结构以上述方式送向制管机24，以便形成中空圆管28，其泡沫内芯带有第二层72。
在图10中，按照图9生产的双层材料表示为一个基本平的片或板70。由于双层材料用作原材料，图10的板或片70包括紧贴在热塑性型材22上的层72。
在图11中示意地画出用于形成双层中空圆管28的另一种结构。在该实施例中，需要材料的层77固定在型材22的底面上，以便生产具有需要材料的构成内芯的层77的中空圆管28。
如上所述，管28的这个实施例是使用制管机24按照相同的方式形成的。采用这种结构，层77可以采用隔热性较高的材料，从而形成一种能够在需要的场合耐高温的低成本的中空圆管28。另外，采用本发明，可以构成这种双层结构的管28，以制成特殊场合所需要的任何需要直径和壁厚的管材。
除了以上述方式形成中空圆管28以外，作为单层热塑性泡沫材料，或作为具有粘合的附加层的多层产品，由本发明生产的圆管和基本平的片或板可以按照许多不同的形状或结构形成。按照这种方式，使用本发明可以制成最终产品所需要的任何需要的形状。
在图12中表示出图1的挤压机21可生产的各种横截面形状的实例。虽然这些替代的形状并不是使用传统挤压设备所能生产的种类繁多的横截面形状和内腔的穷举，但是，这些形状是作为可以实现的各种形状的实例而提出的。另外，采用本发明，相邻的型材侧缘在缠绕心轴30时的粘接使得制成种类繁多的最终产品形状成为可能。
例如，图12中的横截面“A”具有搭接边缘，其用于生产具有粘接每个相邻匝的搭接边缘的中空圆管。另外，如果需要，也可以使用图12横截面“A”的型材生产的中空圆管来生产基本平的片或板。
横截面“G”、“I”和“J”是可生产的带有内腔的型材的实例。这些横截面形状只是种类繁多的可以生产的横截面形状(包括内腔的数目、位置和形状)的实例。但是，这些基本形状的横截面轮廓在生产具有纵向延伸的内腔的基本平的片或板时具有特殊的重要性。
为了生产这种性质的最终产品，如上所述生产中空圆管并对其进行纵向切割。但是，为了保证一个穿过整个片或板的纵向延伸的、基本连续的敞通区域，所得到的板/片产品要以适当的角度切割或修整，以便在得到的最终结构中，构成片或板的每个型材以其侧缘相互平行，因而使其内含有的内腔纵向贯穿整个片或板。这样就可以高效率、低成本地生产各种产品如缓冲垫、保护衬层、漂浮物等。
从上面的描述可以看出，本发明可以提供以前不可能实现的独特的制造方法、生产设备和产品结构，而无需昂贵的生产设备和高成本的生产步骤。但是，使用本说明书中详述的方法和设备，可以生产使用现有技术不能生产的产品。因此，虽然作为本发明的公开内容已经描述了某些实例，但是，这些实例显然只是对发明作总的描述，而并不是对本发明的限定。
因此可以看出上面描述的目的可以有效地实现，由于在实施上述方法中，以及对上述的设备结构和上述得到的产品可以作某些改变而不超出本发明的范围，因而上面的描述及附图所包含的内容只是描述性的，并不是限定性的。

Claims (29)

1.一种连续制造热塑性泡沫产品的方法，包括以下步骤：
A.使用固定的、不可移动的挤压机，连续挤压一长形的、纵向延伸的、基本连续长度的、具有所需横截面形状的热塑性泡沫构件，使热塑性泡沫构件的横截面形状包括从下述组中选择的一种：长方形、正方形、平行四边形、多边形、椭圆形、圆形、卵形及其组合；
B.使所述长形的、纵向延伸的热塑性泡沫构件进入配合工作的拉伸构件，该构件构制得用于把热塑性泡沫构件从挤压机中连续抽拉出来，并喂送进成形装置中，该装置具有固定底部和安装在底部上的可转动心轴，该心轴包括一单个的、纵向延伸的、基本上连续的表面，该表面的长度上具有基本上均匀的横截面；
C.将所述长形的、纵向延伸的热塑性泡沫构件可控地直接缠绕在所述成形装置的所述可转动心轴上，使得热塑性泡沫构件在被缠绕到可转动心轴上时，其相对侧以并置的、侧缘对侧缘的、相邻的关系而定位；
D.当热塑性泡沫构件被缠绕到可转动心轴上时，使热塑性泡沫构件并置的、相邻的侧缘连续地彼此粘合；
E.使基本上为圆柱形的热塑性泡沫构件连续成形，该成形为：
    a.纵向地沿着可转动心轴的长度连续前进；
    b.在心轴终端末端之外连续前进；以及
F.从延伸到可转动心轴终端末端之外的圆柱形热塑性泡沫构件的长度上，反复切割所要求的长度；
从而形成具有所需尺寸或形状的中空热塑性泡沫构件。
2.如权利要求1所述的方法，其特征在于：上述热塑性泡沫构件是由下述组中选择的至少一种构成：聚苯乙烯、聚烯烃、聚乙烯、聚丁烯、聚氨酯、聚尿苷酸、热塑性高弹体、热塑性聚酯、热塑性氨酯、聚酯、乙烯-丙烯酸类共聚物、乙烯-乙酸乙烯酯共聚物、乙烯-丙烯酸甲酯共聚物、乙烯-丙烯酸丁酯共聚物、离聚物、聚丙烯和聚丙烯共聚物。
3.如权利要求1所述的方法，其特征在于：热塑性泡沫构件的横截面进一步限定为实心的。
4.如权利要求1所述的方法，其特征在于：热塑性泡沫构件的横截面进一步限定为包括至少一个基本上穿过其整个长度的纵向延伸的孔。
5.如权利要求1所述的方法，其特征在于：成形装置进一步限定为包括一个支承件，其用于接受并可控地缠绕所述长形的、纵向延伸的、基本连续的热塑性泡沫构件，并用于可控地使所述长形热塑性泡沫构件的第一侧面与其第二侧面形成并置的、侧面对侧面的关系。
6.如权利要求5所述的方法，其特征在于：所述支承件进一步限定为包括一个圆柱形心轴，其构制得连续绕其中心轴线转动，并被定位得便于接受所述长形的、纵向延伸的、基本连续的热塑性泡沫构件，并使所述长形热塑性泡沫构件可连续绕其表面连续包绕，形成在其上包围并支承的圆筒形长形泡沫产品。
7.如权利要求6所述的方法，其特征在于：所述圆柱形心轴进一步限定为包括一个圆形形状，并可卸除地安装在转动的支承构件上，从而可以采用不同直径的心轴。
8.如权利要求6所述的方法，其特征在于：所述心轴进一步限定为包括在其上形成的导向装置，该装置用于接受所述长形的、纵向延伸的、连续的热塑性泡沫构件，并可控地基本以螺旋形绕心轴外表面使热塑性泡沫构件运行，从而使热塑性泡沫构件的侧面彼此形成并置的接触关系。
9.如权利要求8所述的方法，其特征在于：所述粘合步骤是在所述长形的、纵向延伸的热塑性泡沫构件的侧面彼此形成并置的接触关系时加热其侧面而进行的。
10.如权利要求8所述的方法，其特征在于：所述粘合步骤是在热塑性泡沫构件的一个侧面上施加粘合装置，以便当相对的侧面彼此接触时牢固粘接而进行的。
11.如权利要求1所述的方法，其特征在于还包括下列步骤：
G.在与形成的中空热塑性泡沫产品的中心轴线基本垂直的平面上切割所述产品，从而形成精确的所需长度的中空热塑性泡沫产品。
12.如权利要求11所述的方法，其特征在于还包括：
H.在生产热塑性泡沫产品时支承所述产品，从而防止该产品的不合需要的变形。
13.如权利要求11所述的方法，其特征在于还包括下列步骤：
H.在进行所述直径切割步骤之后，沿着所形成的一个壁纵向切割中空热塑性泡沫产品；以及
I.打开所述纵向切割的热塑性产品，形成具有任何所需长度和宽度的基本平坦的板件，从而形成带有任何所需尺寸的板件。
14.如权利要求13所述的方法，其特征在于还包括下列步骤：
J.使打开的板件通过辊装置，以便消除成形过程中在板件上留下的任何弯曲。
15.如权利要求13所述的方法，其特征在于还包括下列步骤：
将打开的板件放置在加热室中，使板件加热直至变平；以及
K.冷却处于平坦形状的板件。
16.如权利要求1所述的方法，其特征在于还包括下列步骤：
G.在所述热塑性泡沫构件送至所述成形装置以前向其一个表面施加至少一个附加材料层；以及
H.将所述附加材料层粘合在热塑性泡沫构件的表面上，从而形成具有任何所需尺寸和形状的多层中空产品。
17.如权利要求16所述的方法，其特征在于：所述粘合步骤是从粘合剂和加热构成的组中选用至少一种而进行。
18.以连续生产操作而制造中空的、基本呈圆筒形的、长形的热塑性泡沫构件的***，该***包括：
A.一个挤压机，其用于生产具有所需横截面形状的长形的、基本连续长度的热塑性泡沫构件；
B.一个拉伸构件，其位于挤压机与成形机之间，该构件构制得用于把热塑性泡沫构件从挤压机中连续抽拉出来，并喂送进成形机中；
C.一个成形机，它包括固定的、不可移动的底部和一单个的、纵向延伸的、基本上连续的支承表面，该表面被定位得接受直接来自拉伸构件的长形的、连续热塑性泡沫构件，并连续地直接与转动的支承表面相关地缠绕所述热塑性构件，从而使热塑性构件的第一侧面与第二侧面形成并置的、相间的对准；
D.粘合装置，它直接与成形机转动的支承表面相关，并与热塑性泡沫构件形成共同工作关系，以便当热塑性泡沫构件的侧面接触时而彼此粘合，使所述侧面牢固地粘合起来，并使基本为圆筒形的泡沫构件得以连续生产；
E.所述支承表面从所述底部轴向延伸一固定长度，以便使圆筒形泡沫构件能被支承，并包括通过所述固定长度为基本均匀的横截面；
F.切割装置，它可移动地安装得与转动支承表面的终端末端成共同工作关系，并被构制得在圆筒形泡沫构件上反复切割所需长度；
从而生产具有任何所需长度和任何所需中空形状的长形的、中空形状的热塑性泡沫构件。
19.如权利要求18所述的***，其特征在于：所述粘合装置进一步限定为包括与成形机相关定位的加热装置，当热塑性泡沫构件的侧面彼此形成并置对准时与所述热塑性泡沫构件形成共同工作关系，所述加热装置是从热空气供应装置和加热表面构成的组中选择一种或多种构成的。
20.如权利要求18所述的***，其特征在于：所述粘合装置进一步限定为包括粘合剂装置。
21.如权利要求18所述的***，其特征在于：所述成形机的支承表面进一步限定为包括一个用于产生具有中空圆筒形形状的长形的泡沫构件圆筒形形状，所述圆筒形构件被安装得可绕其中心轴线连续转动，从而使热塑性泡沫构件可连续缠绕。
22.如权利要求18所述的***，其特征在于：所述***还包括安装在成形机的支承表面上的凸轮装置，其用于从挤压机接受长形的热塑性泡沫构件，并将热塑性泡沫构件引向圆筒形的转动支承表面，使热塑性泡沫构件的第一侧面与第二侧面形成并置的、相间的对准关系。
23.如权利要求18所述的***，其特征在于：所述***还包括切割装置，其用于纵向剖开中空形状的热塑性泡沫构件的至少一个壁，从而产生一个基本平坦的热塑性泡沫板件。
24.如权利要求18所述的***，其特征在于：所述***还包括与成形机配合工作的辊装置，其用于使喂入的热塑性泡沫构件的至少一个表面与前面缠绕的热塑性泡沫构件相应表面对准。
25.如权利要求18所述的***，其特征在于：所述热塑性泡沫构件是由下述组中选择的至少一种构成：聚苯乙烯、聚烯烃、聚乙烯、聚丁烯、聚氨酯、聚尿苷酸、热塑性高弹体、热塑性聚酯、热塑性氨酯、聚酯、乙烯-丙烯酸类共聚物、乙烯-乙酸乙烯酯共聚物、乙烯-丙烯酸甲酯共聚物、乙烯-丙烯酸丁酯共聚物、离聚物、聚丙烯和聚丙烯共聚物。
26.一种连续制造热塑性泡沫产品的方法，包括以下步骤：
A.使用固定的、不可移动的挤压机，连续挤压一长形的、纵向延伸的、基本连续长度的、具有所需横截面形状的热塑性泡沫构件，使热塑性泡沫构件的横截面形状包括从下述组中选择的一种：长方形、正方形、平行四边形、多边形、椭圆形、圆形、卵形及其组合；
B.使所述长形的、纵向延伸的热塑性泡沫构件进入配合工作的拉伸构件，该构件构制得用于把热塑性泡沫构件从挤压机中连续抽拉出来，并喂送进成形装置中，该装置具有固定底部和安装在底部上的可转动心轴，该心轴
    a.包括一单个的、纵向延伸的、基本上连续的表面，该表
面的长度上具有基本上均匀的横截面；以及
    b.被可卸除地安装在所述底部上，以便使任何所需横截
面形状和直径的心轴安装上；
C.将所述长形的、纵向延伸的热塑性泡沫构件可控地直接缠绕在所述成形装置的所述可转动心轴上，使得热塑性泡沫构件在被缠绕到可转动心轴上时，其相对侧以并置的、侧缘对侧缘的、相邻的关系而定位；
D.当热塑性泡沫构件被缠绕到可转动心轴上时，使热塑性泡沫构件并置的、相邻的侧缘连续地彼此粘合；
E.使基本上为圆柱形的热塑性泡沫构件连续成形，该成形为纵向地沿着可转动心轴的长度连续前进，并在心轴终端末端之外连续前进；以及
F.从延伸到可转动心轴终端末端之外的圆柱形热塑性泡沫构件的长度上，反复切割所要求的长度；
从而形成具有所需尺寸或形状的中空热塑性泡沫构件。
27.如权利要求26所述的方法，其特征在于：所述心轴还包括一块安装板，其安装在形成所述心轴的连续表面的一个末端上，所述安装板构制得使心轴与形成机安装接触，以便卸除和更换。
28.以连续生产操作而制造中空的、基本呈圆筒形的、长形的热塑性泡沫构件的***，该***包括：
A.一个固定的、不可移动的挤压机，其用于生产具有所需横截面形状的长形的、基本连续长度的热塑性泡沫构件，该横截面形状包括从下述组中选择的一种：长方形、正方形、平行四边形、多边形、椭圆形、圆形、卵形及其组合；
B.一个拉伸构件，其位于挤压机与成形机之间，该构件构制得用于把热塑性泡沫构件从挤压机中连续抽拉出来，并喂送进成形机中；
C.一个成形机，它包括固定的、不可移动的底部和一单个的、纵向延伸的、基本上连续的支承表面，该表面被定位得接受直接来自拉伸构件的长形的、连续热塑性泡沫构件，并连续地直接与转动的支承表面相关地缠绕所述热塑性构件，从而使热塑性构件的第一侧面与第二侧面形成并置的、相间的对准；
D.粘合装置，它直接与成形机转动的支承表面相关，并与热塑性泡沫构件形成共同工作关系，以便当热塑性泡沫构件的侧面接触时而彼此粘合，使所述侧面牢固地粘合起来，并使基本为圆筒形的泡沫构件得以连续生产；
E.所述支承表面从所述底部轴向延伸一固定长度，以便使圆筒形泡沫构件能被支承，并且
    a.包括通过所述固定长度为基本均匀的横截面；
    b.被可卸除地安装在所述底部上，以便变动着尺寸和形
状的支承表面安装在所述底部上；
F.切割装置，它可移动地安装得与转动支承表面的终端末端成共同工作关系，并被构制得在圆筒形泡沫构件上反复切割所需长度；
从而生产具有任何所需长度和任何所需中空形状的长形的、中空形状的热塑性泡沫构件。
29.如权利要求28所述的***，其特征在于：成形机的支承表面还包括一块安装在该表面一个末端上的安装板，其被构制得与所述成形机的固定底部的可卸除地安装接触，以便卸除和更换。
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EP1030776A1 (en) 2000-08-30
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US6537405B1 (en) 2003-03-25
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HUP0101244A2 (hu) 2001-08-28
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