CN1455724A - 共同模制植绒转移层及其方法 - Google Patents

共同模制植绒转移层及其方法 Download PDF

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CN1455724A
CN1455724A CN01815554A CN01815554A CN1455724A CN 1455724 A CN1455724 A CN 1455724A CN 01815554 A CN01815554 A CN 01815554A CN 01815554 A CN01815554 A CN 01815554A CN 1455724 A CN1455724 A CN 1455724A
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mould
transfer layer
adhesive
suede
barrier
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CN1280081C (zh
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路易斯·B·艾布拉姆斯
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High Voltage Graphics Inc
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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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    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C33/56—Coatings, e.g. enameled or galvanised; Releasing, lubricating or separating agents
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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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    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14778—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the article consisting of a material with particular properties, e.g. porous, brittle
    • B29C45/14811—Multilayered articles
    • 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
    • B32B33/00—Layered products characterised by particular properties or particular surface features, e.g. particular surface coatings; Layered products designed for particular purposes not covered by another single class
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29B11/00—Making preforms
    • B29B11/06—Making preforms by moulding the material
    • B29B11/10—Extrusion moulding
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    • 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
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    • B29C2049/2412—Lining or labelling outside the 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
    • B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
    • B29C49/24—Lining or labelling
    • B29C2049/2414—Linings or labels, e.g. specific geometry, multi-layered or material
    • B29C2049/2429—Multilayered labels
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    • 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
    • B29C41/00—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor
    • B29C41/02—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor for making articles of definite length, i.e. discrete articles
    • B29C41/04—Rotational or centrifugal casting, i.e. coating the inside of a mould by rotating the mould
    • 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
    • B29C41/00—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor
    • B29C41/02—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor for making articles of definite length, i.e. discrete articles
    • B29C41/20—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor for making articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. moulding inserts or for coating articles
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14065—Positioning or centering articles in the mould
    • 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
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/16—Making multilayered or multicoloured 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
    • B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
    • B29C49/24—Lining or labelling
    • 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
    • B29C67/00—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00
    • B29C67/24—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00 characterised by the choice of material
    • B29C67/246—Moulding high reactive monomers or prepolymers, e.g. by reaction injection moulding [RIM], liquid injection moulding [LIM]
    • 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
    • B29K2713/00—Use of textile products or fabrics for preformed parts, e.g. for inserts
    • 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
    • B29K2715/00—Condition, form or state of preformed parts, e.g. inserts
    • B29K2715/006—Glues or adhesives, e.g. hot melts or thermofusible adhesives

Abstract

一种给模制品配备绒表面的方法。该方法包括：设置植绒转移层(2)；在模具(4)中合适位置上固定所述转移层(2)；以及模制该制品，从而将转移层(2)嵌入所述制品的表面中。所述制品可被注入模制。

Description

共同模制植绒转移层及其方法
技术领域
本发明涉及一种具有绒表面的模制品，并且尤其涉及一种将植绒转移层(flocked transfer)应用于模制产品的新的改进方法。
背景技术
出于美观或实用的目的，经常有装饰模制塑料部件的要求。经常用油墨、丝网印刷、曲面印刷、直接静电植绒和热模压来装饰注模制品。这些方法是最经常使用的模制后的工序，该工序需要额外的工艺、成本和时间。另外，成品的质量经常很差，这归因于粘合度低或涂层的不均匀。
最近，发展了模内装饰(In-Mold Decoration)，用于在部件被模制成型时引入装饰的应用，从而去除额外的步骤。然而，伴随着这项技术产生了许多问题，涉及油墨或装饰在向模具中注入树脂时的热量和力的作用过程中保持稳定的失效，涉及使插入的装饰品保留在适当位置的难度，还涉及在注模期间装饰表面被抹掉、垮损或其他的干扰。
发明内容
本发明使用植绒热转移型介质而不是油墨印刷膜插件，这是为了提供一种有绒和均匀涂层的三维结构的装饰，该装饰在部件成型时与热树脂一起模制。利用植绒转移介质，绒质地的装饰被持久地粘附在模制部件的表面。为了达到这一目的，去除了通常在植绒热转移层制造中使用的热熔性粘合剂，因此所述热熔粘合剂将不会从模具上的装饰周围熔化和渗漏出。另外，其它的粘合剂，诸如粘结涂层材料，在将植绒转移层直接注入模制于聚合物模制产品上时，可替代普通热熔剂来防止渗漏并提高与模制树脂的粘合度和(或)化学相容性。
该模具优选具有用来辅助对准和将装饰保持到指定位置的凹槽或定位销或其他机械部件。另外，为了防止模制树脂渗漏进植绒转移层的纤维之间的空隙中，可包括围绕植绒热转移层周边、在模具内制成的“屏障”。
为了进一步适应在注模中引入这种装饰，可对模制工序进行改进，例如通过特意选取具有较低熔点的树脂或通过分两个独立的步骤注入树脂：第一步很“轻柔的”注入使装饰处在指定的位置；紧接着是全压正常注入树脂。
附图说明
图1是植绒转移层被应用于模具中的制品的横截面图，其中该转移层位于制品的顶部。
图2是与图1类似的横截面图，但其中植绒转移层嵌入制品中。
图3是本发明的实施例的顶视平面图，示出了在注模腔内的植绒转移层，其中植绒转移层带有镶边。
图4是本发明的实施例的顶视平面图，示出了在注模腔中的植绒转移层，其中模具包含有镶边。
具体实施方式
图1中示出了处于模具4中的本发明的转移层，该转移层用来和塑料制品6共同模制。图1中，转移层2在制品6的顶部示出。转移层2包括尺寸固定的板8，与需植绒和转移的整个图像相对应，通常是硅酮蜡的传统植绒转移层脱模粘合剂10以与所需图案相反的图案涂敷在所述板8上。绒12可以是人造纤维或任何带有诸如尼龙，聚脂等的传导涂层的其他类型的材料，绒12以任何传统的方式，例如传统的静电方法、振动、空气流动或重力作用植在活性粘合剂10上。将绒12植在粘合剂10上的方法依靠转移层来完成——转移层为一种颜色或几种颜色，转移层包括任何非绒装饰品，等等。因此，转移层本身可以是传统的植绒转移层、Lextra或Lextra 3-D型转移层、诸如位于法国拉勒瓦的Societe D’Enduction et deFlokage制造的绒卷物品(roll good)，来自该处的工件能被切割甚至预先成型，以更适合进入成品表面不平整的模具。绒12的较低端涂有诸如水基乳胶的持久结合粘合剂14，该乳胶把绒粘到物件上，粘合剂14可包含额外的粘合剂，用来增强在模制时转移层对树脂的粘合度。
可将相对不耐用的压敏材料粘合剂16加到在独立的层中的载膜8中，如果没有机械设备可用时，可达到帮助植绒转移层2定位到模具4内的位置上的目的。
图1和图2示出了在模制过程中转移层2覆盖到模制物件6上。转移层2利用压敏粘合剂12定位在模具4中。在模制操作中，可用其它的方法，诸如使用真空装置将转移层2保持在模具4中的合适位置。穿过模主体的真空孔18在模具4中示出。如图所示，转移层2与真空孔18相接触，通过孔18可以抽真空来使转移层保持在所需位置。为了保持转移层处于已完成的塑料部件上的所需位置中，植绒转移层需要被牢固的固定在模具中。如果在模具腔中构造轻微的下凹部(大约1mm)以容纳植绒转移层，那么转移层将与完成的部件的模制塑料表面平齐。这在图2中可看到。如果没有下凹部，植绒装饰将竖立在塑料表面之上，如图1所示。
当转移层被定位在模具中后，该模具被密闭，并且热树脂被注入模具。为了保证在树脂注入期间转移层处于合适位置，用比脱模粘合剂16的熔点低的树脂来消除转移层的错位。另一方面，如果一些被采用的脱模粘合剂的熔点高于树脂的熔点，由于绒为脱模粘合剂隔热，该脱模粘合剂将必定不会首先熔化，并已经交叉结合。因此，这个点的临界状态可能不是必然那样。特定的优选模制方法是反应注模法(RIM)，其中两种基础树脂在刚刚进入模具时被混合在一起，在低热状况下发生了化学反应，并且最终产品的塑料材料在那一瞬间形成。
在一个可选的方法中，低压注入可用在第一步，用来把植绒转移层定位和固定到它的精确位置。一旦该转移层通过首先注入的材料固定在要求的位置，进行第二步，用全压注射来完成部件。
当树脂被注入模具后，模具由环绕模具外部的循环水冷却。虽然在某些采用树脂的注模过程中，如本领域所公知的，冷却水在注模工序和其后可能已循环通过模具。模具能以一些其他传统的方法冷却。由于树脂冷却下来，树脂凝固并与结合粘合剂14形成持久的粘合。当部件被充分地冷却后，打开模具，退出部件。最终，脱模板8和脱模剂10从纤维12剥离，从而在新模制的部件上展示出完成的植绒表面。
上述作为本发明的另一种可选方式，如下所述，绒12可能用其它的方法固定在模制聚合体部件6上。当许多种脱模板和脱模剂可能被首先涂敷在植绒层的上表面上，用来在模制期间使植绒层固定在合适位置上，而不是采用持久的结合粘合剂14来将绒保持在模制部件之内或之上时，可使用诸如可从Bostik有限公司购得的热安装(thermal setting)聚酯来持久地将绒材料的端部粘附到其上，并且同样的，这种板子将与模制聚合体部件6交叉结合成持久的连接，用来在完成的时候在模制部件上形成一个看起来非常自然的绒表面。因此，在注模过程中，热安装聚合材料直接与模制聚合材料交叉结合，并与之固化，形成了持久的植绒产品。
由于转移层上的绒在纤维之间形成空隙后，在模具和转移层周边之间需要形成阻挡层，用来阻止在将树脂注入模具期间，树脂进入这些间隙。参考图3，阻挡层40可以在转移层42周围形成。通过围绕转移层的边缘设置超量的粘合剂10，阻挡层40能在植绒转移层的制造过程中形成。超量的粘合剂10将在转移层的周边形成肋或屏障。
可选地，参考图4，模具50可以配备有当转移层被放置在模具中时，环绕在转移层54周围的阻挡层52。阻挡层52可以是模具50的整体的一部分，或是独立的添加的阻挡层，该阻挡层包含硅树脂、乳胶或其它适合的密封材料。
本发明的内模植绒转移层对需要有绒表面的成品塑料部件特别适用。
根据以上描述，在模制领域的熟练技术人员会想到多种变型。例如，本发明的内模转移层装饰可适用于其他的模制工艺，诸如吹塑法、真空成形法、旋转模制法和传递塑膜法。成品塑料部件不需要是平面，但由于植绒转移层的柔韧性，成品部件可以是圆的，或部件的部分可以隆起。这些仅仅是说明性的。

Claims (13)

1、一种装饰模制品的方法，包括：
设置转移层，该转移层具有植绒层、在植绒一侧的脱模板和在植绒相反侧的结合粘合剂层；
将脱模板固定到模制品在其中被制成的模具的内壁上；
模制所述部件，使树脂接触结合粘合剂层；
冷却模具；
退出部件；
将脱模板从转移层去除。
2、如权利要求1所述的方法，其中，用粘合剂将脱模板粘在模基板上。
3、如权利要求1所述的方法，其中，利用真空装置使脱模板固定在模具上。
4、如权利要求1所述的方法，包括防止树脂渗入绒间的空隙的一个步骤。
5、如权利要求4所述的方法，其中，防止渗入的步骤包括围绕转移层的周边形成屏障。
6、如权利要求5所述的方法，其中，所述屏障通过在模具中设置阻挡层来形成，转移层位于阻挡层内。
7、如权利要求5所述的方法，其中，所述屏障是转移层的一部分，该屏障包括围绕转移层的周边的结合粘合剂(binder adhesive)组成部分。
8、一种装饰模制品的方法，包括：
将脱模剂涂敷在脱模板上；
通过将所述绒的第一端嵌入脱模剂，把绒植入所述脱模剂，从而得到至少一种所排布的植绒图案，从而形成粘附于所述脱模板的预定设计。
围绕所述绒的周边形成阻挡层；
将所述脱模板固定到模具的内表面上；以及
在所述结合粘合剂上模制制品，从而持久地将所述绒粘结到所述制品上。
9、如权利要求8所述的方法，其中，形成所述阻挡层的所述步骤包括：在所述绒上涂敷结合粘合剂；围绕所述绒的周边涂敷所述结合粘合剂。
10、如权利要求8所述的方法，其中，形成所述阻挡层的所述步骤包括：在模具表面设置屏障；将转移层覆盖在所述屏障中的模具上。
11、如权利要求8所述的方法，其中，模制所述制品的步骤包括将熔化的树脂注入模具中。
12、如权利要求11所述的方法，其中，将树脂在第一压力下初始注入，第一压力要足够低，以防止转移层从模具壁错位；然后在第二较高压力下第二次注入树脂。
13、如权利要求11所述的方法，其中，注入的树脂具有比脱模剂低的熔点。
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