CN1294547A - 模制聚烯烃和聚苯基氧化物产品及其生产方法 - Google Patents
模制聚烯烃和聚苯基氧化物产品及其生产方法 Download PDFInfo
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Abstract
聚烯烃和聚苯基氧化物产品(8)如用发泡聚苯乙烯(EPS)或发泡聚丙烯(EPP)制成的产品。乙烯基材料或其它适合装饰材料的“彩箔”或“皮层”(18)与所述产品相关联获得合意的外观和令人满意的外表面。为制备该产品,将皮层放置在阴模模具部件(10)的模腔上。闭合模具,在有或没有真空的协助下,在加入塑料期间使皮层与阴模表面(22)接触。该塑料以选自聚烯烃和聚苯基氧化物颗粒的小颗粒形式加入,已预发泡至密度下降约75%。利用空气压力将颗粒加入模腔(14),并注入蒸汽使颗粒软化并使之粘合成整体。此外,颗粒的外层与彩箔(18)粘合而从模具中取出整体部件。本发明还包括将框架(30)结构加入整块的成品部件中以便于与金属板门或其它支承连接。可用一些种类的固定装置使框架(30)与模具部件(10)相联。然后在模塑步骤期间使框架(30)与塑料部件成为一体,则可容易地使部件与金属板门等相连。
Description
发明背景
本发明涉及模制聚烯烃和聚苯基氧化物(polyphenyloxide)产品及其生产方法。本发明对各种类型产品的生产有实用性,但将针对汽车零部件特别是用于汽车内部因而要求有合意的外观的零部件描述本发明。
所述类型的零部件可包括例如安装在车门内侧的面板。车门典型地由金属板制成,塑料面板直接固定于钢或其它金属板支承上获得合意的外观。US4 766 025描述了这种产品及其生产方法。该专利的背景部分中,参考形成分开的塑料零部件然后在安装期间逐件组装。然后该专利继续描述了以下方法:将乙烯基材料片材拉过模腔,加热,然后利用真空吸入模腔。然后注入可模制的聚氯乙烯或聚氨酯形成包含塑料体和乙烯基材料皮层的整块零部件。
已试图用发泡的聚苯乙烯制造车门面板和其它零部件。此***中,例如1996年3月公开的“塑料技术”中所报道,先模制EPS部件,将聚苯乙烯膜与预先模制的EPS部件一起放入模具中,引入蒸汽使两种材料粘合在一起。
这些现有技术的***存在一些缺陷。因此,用注塑PVC、聚氨酯等制成的零部件相对较重。EPS部件重量较轻但生产方法过于复杂导致生产成本增加。此外,因对于组装该部件与钢或其它金属板门等常用的螺丝及其它固定方法来说塑料的强度不够,在EPS部件的安装中遇到困难。
发明概述
本发明涉及聚烯烃产品如用发泡聚苯乙烯(EPS)或发泡聚丙烯(EPP)制备的产品。用聚苯基氧化物制备的产品也在本发明范围内。乙烯基材料或其它适合装饰材料的“彩箔”或“皮层”与该产品相结合获得合意的外观和令人满意的外表面。
制备该产品的过程中,皮层位于模腔口模或阴模部件的模腔之上。合模并在有或没有真空或空气压力协助下,芯或模具构成部件使所述皮层与阴模表面接触。聚烯烃或聚苯基氧化物以已预发泡至密度下降约75%的小颗粒形式加入。利用空气压力将这些颗粒加入模腔,注入蒸汽使颗粒软化并使之粘结成整体。此外,使颗粒外层与彩箔粘结从而从模具中取出整块零部件。
本发明还设想给所述制成的整块零部件增加框架结构以便于与金属板门或其它支承连接。可利用粘合剂或用连接装置如螺钉增加框架。
在本发明的优选形式中,利用某些种类的紧固件使框架固定就位使框架与模制部件相联。然后在模塑步骤期间使框架与聚烯烃或聚苯基氧化物部件结合在一起,则可容易地将该部件固定于金属板门等之上。
附图简述
图1为本发明模制门面板的正视图;
图2为该门面板沿图1中2-2线的剖面图;
图3为说明模制面板中固定区域构造的该门面板的剖面图;
图4为说明与模制部件相联的模腔和芯部件的剖面图;
图5为模具腔侧的正视图;
图6为模具芯侧的正视图;
图7为模具芯侧的侧视图;
图8为本发明另一实施方式中所采用的框架结构的正视图;
图9为图8框架结构的侧视图;和
图10为本发明另一实施方式的正视图。
优选实施方案的描述
附图说明模制部件及适于使用此模制部件生产的本发明产品。具体地,图1-3中示出聚烯烃或聚苯基氧化物产品8,图4-7中说明模腔模具部件10和阳模芯件12。模具部件10包括模腔14,最好如图5中所示,销钉16位于其上侧。这些销钉或任何其它适合的装置如夹子、Velcro或真空抽吸用于悬挂要用于形成要生产的聚烯烃部件外表面的材料膜片18。如前面所述,这可包括乙烯基类材料,但也包括在模塑期间将与聚烯烃或聚苯基氧化物粘合的任何其它适用的彩箔材料。
该模腔模具部件的模腔表面有多个与真空泵或其它负压装置相通的小孔20。模腔模具部件移至密封模腔的位置时,该负压可用于使膜片18与模腔14的表面相符。
芯模部件12限定了表面22成型形成部件内表面。包括常规填充枪的第一开孔24在间隔的位置位于表面22上,这些开孔与聚烯烃或聚苯基氧化物颗粒源相通。模腔关闭后可利用空气压力源加入这些颗粒。
在表面22中形成另一些开孔26,这些开孔与蒸汽箱28相通(图7)。这些开孔可以是不同尺寸和形状的。例如根据已知的实践,它们可包括安装在模具部件中的直径1/4”的模塞中形成的20个小孔。开孔大小应是使蒸汽能通过但施加负压时塑料不能反向通过的程度。则此蒸汽可用于软化所述颗粒,使颗粒相互粘结,并使膜片18与相邻的颗粒粘合。
在芯模部件中形成孔或其它凹陷23在模制产品中产生整体形成的螺栓等25(图3)。这些螺栓可采取许多形式,它们作为固定装置将模制产品固定于金属板框架等。
芯模部件表面的开孔26和模腔模具部件表面中的开孔20也可与空气压力源相通用于清洁相邻通道,需要时也有助于制件脱模。可采用适合的阀门***选择性地施加负压、加入蒸汽或施加空气压力。
生产本发明部件中,可关闭模具部件,通过开孔26加入蒸汽预热模具。还优选使彩箔18预热。使用乙烯基材料片时,将其预热至100和220°F之间,然后打开模具后利用销钉16悬挂在模腔模具部件1O上。由于该模具使用加热装置,所以也包括对于至少某些应用在合模之后预热该膜片。
利用盘管或本领域常用的其它装置加热模具部件。未填充侧(所述情况下的腔侧)可预热至140和180°F之间,填充侧预热至190和250°F之间。合模期间或之后优选施加负压使膜片18与模具表面相符。芯模部件闭合时,这将有助于膜片的成形,可通过芯模部件中的开孔26由空气压力施加附加的压力。必须使膜片18与更复杂的表面构型相符时这特别有利。
在空气压力下通过芯模部件中的填充枪开孔24加入颗粒,由于不希望使颗粒压缩,所以此压力较低。一旦颗粒就位后,既通过将开孔26与真空源22相连抽出空气。为使颗粒之间和颗粒与皮层之间粘合,除去空气是关键的。
然后通过开孔26加入蒸气使颗粒软化并如上所述使之粘合。用阀门***使开孔26与真空源22相连通过开孔26除去过量湿气。与用聚烯烃颗粒的传统模塑相反,由于膜片18阻塞了由阴模部件限定的通道,所以仅在一侧加入蒸汽。典型地采用4至9巴的蒸汽压力。模具部件表面涂有PTFE(例如Teflon)涂层以便于模制部件的脱模。还发现此涂层促使膜片18与模具部件表面相符性提高,因为在加入颗粒之前施加真空和/或其它压力时该膜片更易在表面上移动。
作为本发明优选实施方案的例子,闭合模具部件10和12,使之分别预热至176°F和230°F。腔侧预热至较低温度,因为加热盘管与有蒸汽箱28的芯侧相联(图7)。在蒸汽箱内施加负压通过开孔26从腔中抽出过剩热量。
将预热的乙烯基材料片悬挂在销钉上,再合模。优选先较慢地移动逐渐将膜片压入模腔。然后向模腔模具部件施加负压从而通过开孔20从模腔中抽出空气。从而使膜片与模腔表面相符,然后使模具完全封闭。
然后通过芯模部件中的开孔26施加空气压力以确保皮层与模腔表面完全相符。之后用填充枪通过开孔24加入聚烯烃颗粒。
然后通过开孔26施加负压清除模具中的空气和湿气。如前面所述,为获得良好的粘合条件,特别需要除去空气。然后通过开孔26压入蒸汽(4至9巴),使颗粒相互粘合并使膜片18与相邻的颗粒层粘合。
利用芯模部件的通道通过在其中循环致冷剂发生冷却。模制部件稳定后,通过开孔26施加空气压力以辅助模具打开后部件的分离。
图8和9示出设计用于与本发明部件类型相关联的支承框架30。此部件可由金属或硬塑料制成,有足够的结构完整性以与金属板门等固定。
使框架30成型用于与金属板门相联。框架包括用于与门活动连接的装置,包括带钩凸缘32和限定“销槽”的元件34,用于接收常用于与门相联的有扩大头部的销钉。元件34均包括下部扩大的开孔用于接收扩大的销钉头部,和上部变窄的槽用于接收销体。这些或其它任何常用于使框架固定于门的装置包括其它形式的槽、孔和钩均可使用。框架30包括限定开孔或其它固定装置42的横向元件40。这些及其变形可用于接收烟灰盒、玻璃升降器、门把手、装饰固定装置、侧缓冲器、安全气囊等。
可利用粘合剂、锁环、螺钉、销钉、导线、热粘合或摩擦焊使框架30与聚烯烃或聚苯基氧化物部件相结合。还包括例如在加入颗粒之前将框架暂时固定于芯模部件12上将框架安装在模具内。在此情况下,框架将由与颗粒如聚丙烯相容的材料制成。然后在模塑操作过程中部件与框架结合而形成整体结构。
图10说明装饰件38如铺毯段固定于其上的框架36。在此实施方案中,将模制部件与框架上部相符,从而得到上部乙烯基材料外表面和下部铺毯表面的复合体。此组合可有许多变化。
显然框架的构型可相对于聚烯烃部件采取几种形式。因此,可认为聚烯烃或聚苯基氧化物部件是框架的装饰表层,框架可以为各种尺寸,甚至与部件内侧共存。框架应包封在部件之上、周围、侧面或下面。框架的任何暴露部分本身应有装饰层以补充该部分。
如前面所述,部件的皮层18可以是乙烯基材料,但也包括可与聚烯烃或聚苯基氧化物粘合的其它材料,包括织物、TPO、聚氨酯、皮革、纸或筛网。还包括所述彩箔或皮层是非相容材料,有由所述材料之一形成的衬里。
本发明的聚烯烃或聚苯基氧化物部分可包括整体的扶手区,有要求的形状且有由聚烯烃或聚苯基氧化物提供的松软感和柔软的侧面缓冲区。因此不需象采用硬塑料时模制分开的部件,部件的此区域和其它区域将有这些特点。
该部件可容易地模制成有整体模制的管、槽或通道提供导线或HVAC空气流动室。这些区域的盖板也可容易地模制成有整体存在的铰链。
由于所述部件和方法的多功能性,用较少的生产和组装步骤获得比常用部件轻75%的面板组件。所述聚烯烃或聚苯基氧化物因对路面噪音和热传递的阻挡性更好并有改善的吸音性以增强内部音响***而具有附加的优点。如前面所述,侧面的缓冲也得到改善。除节省劳动之外,因热能消耗显著降低,生产效率相对注塑而改善。
应理解在不背离本发明精神的情况下可对本发明做各种改变和增加,本发明范围由后面的权利要求书限定。
Claims (18)
1.一种有装饰皮层的模制塑料产品的生产方法,所述方法利用阳模和阴模模具部件限定内表面形成与所要产品形状相对应的模腔,包括在所述模具部件中与其内部相通的开孔、与至少一些所述开孔相通用于将塑料颗粒和蒸汽输入所述模腔的装置、和与至少一些所述开孔相通用于给所述内部施加负压的装置,所述方法包括以下步骤:使所述要求皮层材料的膜片叠置于一个模具部件的内部,闭合所述模具部件,使所述膜片与所述一个模具部件的内表面相符,将选自聚烯烃和聚苯基氧化物颗粒的颗粒输入所述模腔,给所述模腔施加负压从模腔中除去空气,将蒸汽输入所述模腔使所述颗粒软化并使所述颗粒相互粘合并使所述膜片与相邻的颗粒粘合,给所述模腔施加负压从模腔中除去过量的湿气,然后从所述模腔中取出所述产品。
2.权利要求1的方法,包括给所述一模具部件的内部施加负压使所述膜片与所述一模具部件内表面相符的步骤。
3.权利要求1的方法,其中在放置所述膜片的步骤之后至少部分地与所述模具部件的闭合相对应,使所述膜片向所述一模具部件的所述内表面移动。
4.权利要求1的方法,包括相对所述一模具部件放置所述膜片之前,将所述膜片预热至在100和220°F之间的温度的步骤。
5.权利要求1的方法,包括与至少一些所述开孔相通用于施加空气压力的装置,并包括给所述膜片施加空气压力辅助所述膜片与所述一模具部件的所述内表面相符的步骤。
6.权利要求1的方法,包括将所述一模具部件预热至在140和180°F之间的温度和将另一模具部件预热至在190和250°F之间的温度的步骤,然后将所述颗粒输入所述模腔。
7.权利要求1的方法,包括用聚四氟乙烯涂覆所述内表面的步骤。
8.权利要求1的方法,包括使支承框架与所述塑料产品相连的步骤。
9.权利要求8的方法,包括在闭合相同模具部件之前将所述支承框架放入所述模腔中的步骤。
10.根据权利要求1的方法生产的模制塑料部件。
11.权利要求10的模制塑料部件,其中所述膜片包括乙烯基材料。
12.权利要求1O的模制塑料部件,其中所述膜片包括不同材料的复合体,其中所述膜片限定用于与所述颗粒粘合的内表面。
13.根据权利要求9的方法生产的模制塑料部件。
14.权利要求13的模制塑料部件,其中所述支承框架限定使所述部件与金属板支承相连的装置。
15.权利要求13的模制塑料部件,其中所述框架由聚丙烯制成。
16.权利要求14的模制塑料部件,包括汽车用内部面板,所述金属板支承为所述汽车的部件。
17.权利要求14的模制塑料部件,包括所述支承框架放置在所述模腔内时与所述支承框架相连的装饰件。
18.权利要求10的模制塑料部件,包括整体模制成所述部件的固定装置。
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
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US08/963,955 US6063460A (en) | 1997-11-04 | 1997-11-04 | Molded polyolefin and polyphenyloxide products and method for production |
US08/963,955 | 1997-11-04 |
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CN1294547A true CN1294547A (zh) | 2001-05-09 |
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ID=25507943
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CN98811447A Pending CN1294547A (zh) | 1997-11-04 | 1998-10-22 | 模制聚烯烃和聚苯基氧化物产品及其生产方法 |
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US (1) | US6063460A (zh) |
EP (1) | EP1028837A1 (zh) |
JP (1) | JP2001521835A (zh) |
KR (1) | KR20010031760A (zh) |
CN (1) | CN1294547A (zh) |
AR (1) | AR016659A1 (zh) |
AU (1) | AU1116399A (zh) |
BR (1) | BR9813931A (zh) |
CA (1) | CA2308609A1 (zh) |
EA (1) | EA200000486A1 (zh) |
HU (1) | HUP0100563A3 (zh) |
NO (1) | NO20002202L (zh) |
PL (1) | PL340423A1 (zh) |
WO (1) | WO1999022923A1 (zh) |
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CN100402264C (zh) * | 2002-03-19 | 2008-07-16 | 株式会社Jsp | 复合发泡聚丙烯树脂模制品及其制备方法 |
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FR2859426B1 (fr) * | 2003-09-10 | 2006-12-08 | Valeo Systemes Dessuyage | Habillage de module d'equipement dont une paroi porte une camera de vision arriere |
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EP1813408A1 (de) * | 2006-01-26 | 2007-08-01 | Basf Aktiengesellschaft | Verfahren zum Befüllen von Formwerkzeugen mit expendierten Polymerpartikeln |
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CZ302660B6 (cs) * | 2010-02-16 | 2011-08-24 | Novopol A.S. | Zpusob výroby výlisku a výlisek |
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-
1997
- 1997-11-04 US US08/963,955 patent/US6063460A/en not_active Expired - Fee Related
-
1998
- 1998-10-22 BR BR9813931A patent/BR9813931A/pt not_active Application Discontinuation
- 1998-10-22 EP EP19980953911 patent/EP1028837A1/en not_active Ceased
- 1998-10-22 CN CN98811447A patent/CN1294547A/zh active Pending
- 1998-10-22 CA CA 2308609 patent/CA2308609A1/en not_active Abandoned
- 1998-10-22 JP JP2000518827A patent/JP2001521835A/ja active Pending
- 1998-10-22 EA EA200000486A patent/EA200000486A1/ru unknown
- 1998-10-22 PL PL34042398A patent/PL340423A1/xx unknown
- 1998-10-22 WO PCT/US1998/022431 patent/WO1999022923A1/en not_active Application Discontinuation
- 1998-10-22 HU HU0100563A patent/HUP0100563A3/hu unknown
- 1998-10-22 KR KR1020007004825A patent/KR20010031760A/ko not_active Application Discontinuation
- 1998-10-22 AU AU11163/99A patent/AU1116399A/en not_active Abandoned
- 1998-11-02 AR ARP980105501 patent/AR016659A1/es unknown
-
2000
- 2000-04-28 NO NO20002202A patent/NO20002202L/no not_active Application Discontinuation
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CN100402264C (zh) * | 2002-03-19 | 2008-07-16 | 株式会社Jsp | 复合发泡聚丙烯树脂模制品及其制备方法 |
WO2007059656A1 (fr) * | 2005-11-28 | 2007-05-31 | Tzongin Yeh | Procede pour la preparation d'un produit expanse avec de la peau et produit obtenu par ce procede |
Also Published As
Publication number | Publication date |
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BR9813931A (pt) | 2000-09-19 |
JP2001521835A (ja) | 2001-11-13 |
EP1028837A1 (en) | 2000-08-23 |
AR016659A1 (es) | 2001-07-25 |
NO20002202D0 (no) | 2000-04-28 |
PL340423A1 (en) | 2001-02-12 |
US6063460A (en) | 2000-05-16 |
HUP0100563A3 (en) | 2001-07-30 |
AU1116399A (en) | 1999-05-24 |
KR20010031760A (ko) | 2001-04-16 |
CA2308609A1 (en) | 1999-05-14 |
WO1999022923A1 (en) | 1999-05-14 |
EA200000486A1 (ru) | 2000-10-30 |
HUP0100563A2 (hu) | 2001-06-28 |
NO20002202L (no) | 2000-07-03 |
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