WO1991003372A1 - Variable thickness foam plank - Google Patents
Variable thickness foam plank Download PDFInfo
- Publication number
- WO1991003372A1 WO1991003372A1 PCT/US1990/002670 US9002670W WO9103372A1 WO 1991003372 A1 WO1991003372 A1 WO 1991003372A1 US 9002670 W US9002670 W US 9002670W WO 9103372 A1 WO9103372 A1 WO 9103372A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- product
- thermoplastic
- webs
- sheets
- foam
- Prior art date
Links
Classifications
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- 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
- B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
- B32B7/04—Interconnection of layers
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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
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/74—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by welding and severing, or by joining and severing, the severing being performed in the area to be joined, next to the area to be joined, in the joint area or next to the joint area
- B29C65/743—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by welding and severing, or by joining and severing, the severing being performed in the area to be joined, next to the area to be joined, in the joint area or next to the joint area using the same tool for both joining and severing, said tool being monobloc or formed by several parts mounted together and forming a monobloc
- B29C65/7437—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by welding and severing, or by joining and severing, the severing being performed in the area to be joined, next to the area to be joined, in the joint area or next to the joint area using the same tool for both joining and severing, said tool being monobloc or formed by several parts mounted together and forming a monobloc the tool being a perforating tool
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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
- 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
- B29C65/18—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools
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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
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/78—Means for handling the parts to be joined, e.g. for making containers or hollow articles, e.g. means for handling sheets, plates, web-like materials, tubular articles, hollow articles or elements to be joined therewith; Means for discharging the joined articles from the joining apparatus
- B29C65/7858—Means for handling the parts to be joined, e.g. for making containers or hollow articles, e.g. means for handling sheets, plates, web-like materials, tubular articles, hollow articles or elements to be joined therewith; Means for discharging the joined articles from the joining apparatus characterised by the feeding movement of the parts to be joined
- B29C65/7888—Means for handling of moving sheets or webs
- B29C65/7891—Means for handling of moving sheets or webs of discontinuously moving sheets or webs
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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
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/01—General aspects dealing with the joint area or with the area to be joined
- B29C66/05—Particular design of joint configurations
- B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
- B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
- B29C66/112—Single lapped joints
- B29C66/1122—Single lap to lap joints, i.e. overlap joints
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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
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
- B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
- B29C66/45—Joining of substantially the whole surface of the articles
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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
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—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
- B29C66/71—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 composition of the plastics material of the parts to be joined
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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
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—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
- B29C66/72—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 structure of the material of the parts to be joined
- B29C66/727—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 structure of the material of the parts to be joined being porous, e.g. foam
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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
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- 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
- B29C66/832—Reciprocating joining or pressing tools
- B29C66/8322—Joining or pressing tools reciprocating along one axis
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- 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
- B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form
- B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
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- 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
- B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
- B32B37/06—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the heating method
- B32B37/065—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the heating method resulting in the laminate being partially bonded
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- 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
- B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
- B32B37/10—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
-
- 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
- B32B38/00—Ancillary operations in connection with laminating processes
- B32B38/0032—Ancillary operations in connection with laminating processes increasing porosity
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- 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
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
-
- 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
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
- B32B5/32—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed at least two layers being foamed and next to each other
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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
- 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
- B29C65/18—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools
- B29C65/22—Heated wire resistive ribbon, resistive band or resistive strip
- B29C65/221—Heated wire resistive ribbon, resistive band or resistive strip characterised by the type of heated wire, resistive ribbon, band or strip
- B29C65/222—Heated wire resistive ribbon, resistive band or resistive strip characterised by the type of heated wire, resistive ribbon, band or strip comprising at least a single heated wire
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- 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
- B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
- B29K2105/04—Condition, form or state of moulded material or of the material to be shaped cellular or porous
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2009/00—Layered products
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- 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
- B32B2266/00—Composition of foam
- B32B2266/02—Organic
- B32B2266/0214—Materials belonging to B32B27/00
- B32B2266/025—Polyolefin
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- 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
- B32B2305/00—Condition, form or state of the layers or laminate
- B32B2305/02—Cellular or porous
- B32B2305/026—Porous
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
- Y10T156/10—Methods of surface bonding and/or assembly therefor
- Y10T156/1052—Methods of surface bonding and/or assembly therefor with cutting, punching, tearing or severing
- Y10T156/1054—Methods of surface bonding and/or assembly therefor with cutting, punching, tearing or severing and simultaneously bonding [e.g., cut-seaming]
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
- Y10T156/10—Methods of surface bonding and/or assembly therefor
- Y10T156/1052—Methods of surface bonding and/or assembly therefor with cutting, punching, tearing or severing
- Y10T156/1056—Perforating lamina
- Y10T156/1057—Subsequent to assembly of laminae
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24273—Structurally defined web or sheet [e.g., overall dimension, etc.] including aperture
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24273—Structurally defined web or sheet [e.g., overall dimension, etc.] including aperture
- Y10T428/24322—Composite web or sheet
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24802—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
- Y10T428/24826—Spot bonds connect components
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/249921—Web or sheet containing structurally defined element or component
- Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
- Y10T428/249981—Plural void-containing components
Definitions
- This invention relates to a thick and controllably rigidified thermoplastic foam product and a method of manufacture thereof.
- Hot pin perforation bonding is used in the present invention. This bonding technique is shown in ⁇ . S. Patent No. 4,758,297 - Calligarich, which discloses a method of using hot pin perforation bonding to laminate one ply of thermoplastic film to one ply of cellular fiber fabric. The process described therein is a continuous one using a heated roller with project- ing pins.
- Hot pin bonding has been used for many years in a commercial product by Ametek, Inc., the Assignee of the present invention, to produce a thin multi-layer flexible polypropylene foam sheet material.
- the resultant product retains the flexibility of the original starting material sheets, and the pins generally do not fully perforate the material. Occasionally the hot pins may cause perforations in the sheet material. These perforations may be formed intentionally, to provide ventilation, or unintentionally due to overheated pins. Still, this product in all known forms is very flexible and rela- tively thin (less than one-half inch thick).
- Thermoplastic foam e.g. polyethylene and polypro ⁇ pylene foam has been made by extruding or otherwise molding a sheet of resin, in which is incorporated a dispersed blowing agent. Upon decompression, as it leaves the extrusion die for example, the blowing agent expands and escapes as the resin solidifies. A foam product, ideally of flexible, micro-cellular structure, results. If the resin sheet is too thick, however, the blowing and hardening reactions are not coordinated and an unfoamed or poorly foamed product results.
- a dispersed blowing agent e.g. polyethylene and polypro ⁇ pylene foam
- the product of this invention is a thick, soft thermoplastic foam sheet material, or "plank” of controlled (or controllably pre-determined) rigidity.
- plank refers to a generally flat product, usually of indefinite length and with a thickness in a range from one half to several (generally no more than five) inches. This plank com ⁇ prises a plurality of thin flexible lamina, preferably of microcellular polypropylene foam, held together and made rigid by melt-bonded perforations.
- thermoplastic foam material preferably micro- cellular polypropylene
- a plurality of continuous webs of thermoplastic foam material are simultaneously fed, either in discrete lengths or indefinite lengths, from supply rolls to a forming table where they overlay one another.
- Successive lengths of material are compressed, then perforated with hot pins, which cause localized melting through the thickness of the resulting laminate.
- the hot pins are removed, and locally melted areas cooled, the laminate product is released from compres ⁇ sion and another length is brought onto the forming table. In this way, a continuous hot pin bonded foam plank is produced. The plank is then cut to any desired length by conventional means.
- the face of the resultant product is rela ⁇ tively soft, while the laminated product, in general, is relatively rigid, to a degree dependent on the temperature, size and spacing of the pins and the compression exerted on the material during the hot pin perforation process.
- Fig. 1 is a schematic view of the process of the present invention.
- Fig. 2 is a cross-sectional perspective view of the product of the present invention.
- Feed webs 5 may be up to 78 inches wide. These webs are supplied from supply roll ⁇ , not shown. Preferably, the ends of the rolled webs are staggered so that the breaks in the webs which occur at the ends of the rolls are also staggered. Therefore, one continuous plank of foamed material is produced with occasional breaks in individual layers.
- Feed webs 5 are directed to the forming table of a hot pin perforating apparatus by nip roller 22 and feed rollers 20. Feed webs 5 are then passed through pre- compression nip rollers 21. Throughout the process, the feed webs move intermittently. The process is a batch process performed on continuous webs of feed material.
- Successive predetermined lengths of feed webs 5 are moved and held in position, overlying one another on fixed platen 11 of the forming table. Compression platen 12 is then lowered over feed webs 5. Compres ⁇ sion platen 12 compresses the thermoplastic foam feed webs 5, while hot pin platen 13 is lowered toward the feed webs. Compression platen 12 (and preferably fixed platen 11 also) is equipped with holes to allow hot pins 14 to penetrate through feed webs 5. As hot pin platen 13 is lowered, hot pins 14 penetrate the thermo ⁇ plastic foam webs 5, melting holes through the thermo ⁇ plastic foam webs. The melted material lines the holes thus produced and bonds feed webs 5 together into a continuous foam plank 10. Hot pin platen 13 is then withdrawn, and the thermoplastic material is allowed to cool briefly. Compression platen 12 is then lifted and another predetermined length of feed webs 5 is moved and held in position on fixed platen 11, so that the next section may be bonded.
- the resultant continuous foam plank 10 is taken away by drive roller 15 and nip roller 18.
- Drive roller 15 may drive the entire system of feed webs 5.
- Cutter 16 may be a knife blade, heated wire or any other conventional means used for cutting thermoplastic foam material.
- Foam planks 10a may then be removed by take-away rollers 19 and stacked and shipped to their destination.
- One resultant foam plank product 10a is shown in Fig. 2.
- the material between holes 17 (caused by hot pins 14) expands slightly and a quilted effect is achieved.
- the plank experiences residual compression in the vicinity of the holes, that is webs 5 remain compressed as compared to their non-bonded state.
- the resultant foam planks 10a are very strong and light ⁇ weight. They can also be extremely non-abrasive, depending upon the material from which they were made. They will have nearly the same non-abrasive qualities as feed webs 5.
- Foam planks 10a are rigid and rela ⁇ tively inflexible, in contrast to feed webs 5. This rigidity is believed to result, at least in part, from the pre-bonding compression of foam webs 5.
- This rigidity is controllable.
- the rigidity and density of the plank vary with the amount of compression used. Density is further variable through selection of the starting feed webs. Thicker feed webs tend to be less dense than thinner webs (i.e. one-eighth inch thick webs are less dense than one-thirty- ⁇ econd inch thick webs). Therefore, thicker feed webs result in a plank with a lower density than if thinner feed webs are used.
- the rigidity also depends on the size and spacing of the hot pins; the amount of compression force used; the thickness of the foam web starting material; and the overall thickness of the plank, as well as the flexibility/compressibility characteristics of the starting material.
- the resultant product is between 1/2 and 5 inches thick, and is comprised of between 5 and 150 sheets of 1/32 to 1/8 inch thickness and up to 78 inches width each.
- the compression used in producing the laminate is preferably 5 to 15 psi.
- Hot pins of between 3/16 and 5/16 inch diameter and length sufficient to pene ⁇ trate all of the individual sheets (at least 5 inches) are used at a spacing of about 1 inch, or 1 pin per square inch and a temperature of between 400°F and 500°F, to produce a plank having a density of from .5 lb/ft 3 to 1.5 lb/ft 3 .
- foam planks 10a may be easily cut and shaped using knives, heated wires, or any known method for cutting thermoplastic material.
- the planks may also be trimmed to approximately 72 inches in width from the 78 inch wide starting material.
- Foam planks 10a are durable and lightweight and there ⁇ fore useful for shipping fragile materials.
- the planks may be coated, for instance with anti-static coating, or alternatively, may be produced from feed webs which contain anti-static treatment, if the product which they are to protect so requires.
Abstract
Successive predetermined lengths of feed webs (5) are moved and held in position, overlying one another on fixed platen (11) of the forming table. Compression platen (12) is then lowered over feed webs (5). Compression platen (12) compresses the thermoplastic foam feed webs (5), while hot pin platen (13) is lowered toward the feed webs. Compression platen (12) (and preferably fixed platen (11) also) is equipped with holes to allow hot pins (14) to penetrate through feed webs (5). As hot pin platen (13) is lowered, hot pins (14) penetrate the thermoplastic foam webs (5), melting holes through the thermoplastic foam webs. The melted material lines the holes thus produced and bonds feed webs (5) together into a continuous foam plank (10).
Description
VARIABLE THICKNESS FOAM PLANK
BACKGROUND OF THE INVENTION
Field of the Invention
This invention relates to a thick and controllably rigidified thermoplastic foam product and a method of manufacture thereof.
Description of Prior Art
Hot pin perforation bonding is used in the present invention. This bonding technique is shown in ϋ. S. Patent No. 4,758,297 - Calligarich, which
discloses a method of using hot pin perforation bonding to laminate one ply of thermoplastic film to one ply of cellular fiber fabric. The process described therein is a continuous one using a heated roller with project- ing pins.
Hot pin bonding has been used for many years in a commercial product by Ametek, Inc., the Assignee of the present invention, to produce a thin multi-layer flexible polypropylene foam sheet material.
In this case, the resultant product retains the flexibility of the original starting material sheets, and the pins generally do not fully perforate the material. Occasionally the hot pins may cause perforations in the sheet material. These perforations may be formed intentionally, to provide ventilation, or unintentionally due to overheated pins. Still, this product in all known forms is very flexible and rela- tively thin (less than one-half inch thick).
Thermoplastic (e.g. polyethylene and polypro¬ pylene) foam has been made by extruding or otherwise molding a sheet of resin, in which is incorporated a dispersed blowing agent. Upon decompression, as it leaves the extrusion die for example, the blowing agent expands and escapes as the resin solidifies. A foam product, ideally of flexible, micro-cellular structure, results. If the resin sheet is too thick, however, the
blowing and hardening reactions are not coordinated and an unfoamed or poorly foamed product results.
Summary of the Invention
The product of this invention is a thick, soft thermoplastic foam sheet material, or "plank" of controlled (or controllably pre-determined) rigidity. The term "plank" as used here refers to a generally flat product, usually of indefinite length and with a thickness in a range from one half to several (generally no more than five) inches. This plank com¬ prises a plurality of thin flexible lamina, preferably of microcellular polypropylene foam, held together and made rigid by melt-bonded perforations.
In accordance with the method of manufacture of the present invention, a plurality of continuous webs of thermoplastic foam material, preferably micro- cellular polypropylene, are simultaneously fed, either in discrete lengths or indefinite lengths, from supply rolls to a forming table where they overlay one another. Successive lengths of material are compressed, then perforated with hot pins, which cause localized melting through the thickness of the resulting laminate. After the hot pins are removed, and locally melted areas cooled, the laminate product is released from compres¬ sion and another length is brought onto the forming
table. In this way, a continuous hot pin bonded foam plank is produced. The plank is then cut to any desired length by conventional means.
The face of the resultant product is rela¬ tively soft, while the laminated product, in general, is relatively rigid, to a degree dependent on the temperature, size and spacing of the pins and the compression exerted on the material during the hot pin perforation process.
Brief Description of the Drawings
Fig. 1 is a schematic view of the process of the present invention.
Fig. 2 is a cross-sectional perspective view of the product of the present invention.
Detailed Description of the Preferred Embodiment
Referring to Fig. 1, individual webs 5, of thermoplastic foam, preferably microcellular polypro¬ pylene such as that sold by Ametek as Microfoam, and typically from about one-thirty-second to one-eighth inch thick, are used as feed. Feed webs 5 may be up to 78 inches wide. These webs are supplied from supply
rollε, not shown. Preferably, the ends of the rolled webs are staggered so that the breaks in the webs which occur at the ends of the rolls are also staggered. Therefore, one continuous plank of foamed material is produced with occasional breaks in individual layers. Feed webs 5 are directed to the forming table of a hot pin perforating apparatus by nip roller 22 and feed rollers 20. Feed webs 5 are then passed through pre- compression nip rollers 21. Throughout the process, the feed webs move intermittently. The process is a batch process performed on continuous webs of feed material.
Successive predetermined lengths of feed webs 5 are moved and held in position, overlying one another on fixed platen 11 of the forming table. Compression platen 12 is then lowered over feed webs 5. Compres¬ sion platen 12 compresses the thermoplastic foam feed webs 5, while hot pin platen 13 is lowered toward the feed webs. Compression platen 12 (and preferably fixed platen 11 also) is equipped with holes to allow hot pins 14 to penetrate through feed webs 5. As hot pin platen 13 is lowered, hot pins 14 penetrate the thermo¬ plastic foam webs 5, melting holes through the thermo¬ plastic foam webs. The melted material lines the holes thus produced and bonds feed webs 5 together into a continuous foam plank 10. Hot pin platen 13 is then withdrawn, and the thermoplastic material is allowed to cool briefly. Compression platen 12 is then lifted and
another predetermined length of feed webs 5 is moved and held in position on fixed platen 11, so that the next section may be bonded.
The resultant continuous foam plank 10 is taken away by drive roller 15 and nip roller 18. Drive roller 15 may drive the entire system of feed webs 5. When a predetermined length of continuous foam plank 10 has been produced, it is cut by cutter 16 into indi¬ vidual planks 10a. Cutter 16 may be a knife blade, heated wire or any other conventional means used for cutting thermoplastic foam material. Foam planks 10a may then be removed by take-away rollers 19 and stacked and shipped to their destination.
One resultant foam plank product 10a is shown in Fig. 2. Upon release of compression by compression platen 12, the material between holes 17 (caused by hot pins 14) expands slightly and a quilted effect is achieved. The plank experiences residual compression in the vicinity of the holes, that is webs 5 remain compressed as compared to their non-bonded state. The resultant foam planks 10a are very strong and light¬ weight. They can also be extremely non-abrasive, depending upon the material from which they were made. They will have nearly the same non-abrasive qualities as feed webs 5. Foam planks 10a are rigid and rela¬ tively inflexible, in contrast to feed webs 5. This rigidity is believed to result, at least in part, from
the pre-bonding compression of foam webs 5. This rigidity is controllable. The rigidity and density of the plank vary with the amount of compression used. Density is further variable through selection of the starting feed webs. Thicker feed webs tend to be less dense than thinner webs (i.e. one-eighth inch thick webs are less dense than one-thirty-εecond inch thick webs). Therefore, thicker feed webs result in a plank with a lower density than if thinner feed webs are used.
The rigidity also depends on the size and spacing of the hot pins; the amount of compression force used; the thickness of the foam web starting material; and the overall thickness of the plank, as well as the flexibility/compressibility characteristics of the starting material.
In the preferred embodiment of this inven¬ tion, the resultant product is between 1/2 and 5 inches thick, and is comprised of between 5 and 150 sheets of 1/32 to 1/8 inch thickness and up to 78 inches width each. The compression used in producing the laminate is preferably 5 to 15 psi. Hot pins of between 3/16 and 5/16 inch diameter and length sufficient to pene¬ trate all of the individual sheets (at least 5 inches) are used at a spacing of about 1 inch, or 1 pin per square inch and a temperature of between 400°F and
500°F, to produce a plank having a density of from .5 lb/ft3 to 1.5 lb/ft3.
The resultant material, foam planks 10a, may be easily cut and shaped using knives, heated wires, or any known method for cutting thermoplastic material. The planks may also be trimmed to approximately 72 inches in width from the 78 inch wide starting material. Foam planks 10a are durable and lightweight and there¬ fore useful for shipping fragile materials. The planks may be coated, for instance with anti-static coating, or alternatively, may be produced from feed webs which contain anti-static treatment, if the product which they are to protect so requires.
The invention has been described as the method of manufacturing a multi-ply laminate and the product of such manufacture in the best mode known to the applicants. However, it will be apparent that the invention may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the appended claims.
Claims
1. A relatively and controllably rigid, lightweight flat thermoplastic foam product comprising:
a plurality of laminated thermoplastic foam sheets bonded to one another by melt-bound perforations.
10
2. The product of claim 1 wherein said thermoplastic sheets are hot pin perforation bonded.
I5 * The product of claim 1 wherein said thermoplastic is polypropylene.
4. The product of claim 2 wherein said 20 thermoplastic is microcellular polypropylene.
5. The product of claim 1 wherein said thermoplastic is polyethylene.
25
6. The product of claim 2 wherein said thermoplastic is polyethylene.
7. A relatively and controllably rigid flat foamed thermoplastic product comprising:
a laminate of a plurality of foamed thermoplastic sheets, said sheets bonded to one another by non-foamed material lining holes through said sheets.
8. The product of claim 7 wherein said sheets are hot pin perforation bonded.
9. The product of claim 7 wherein said thermoplastic is polypropylene.
10. The product of claim 7 wherein said thermoplastic is polyethylene.
11. The product of claim 8 having residual compressive forces among said sheets.
12. A method for making a rigid flat foamed thermoplastic product comprising the steps of:
bringing into laminated relationship at least a portion of each of a plurality of continuous webs of foamed thermoplastic material;
compressing said portions in a direction, perpendicular to the length and width of said sheets, and parallel to the thickness of said sheets;
bonding said portions to one another; and
releasing said portions from compression.
13. The method of claim 12, wherein said portions are bonded by forming melt-surrounded perforations therethrough.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US07/403,121 US5066531A (en) | 1989-09-05 | 1989-09-05 | Variable thickness foam plank |
US403,121 | 1989-09-05 |
Publications (1)
Publication Number | Publication Date |
---|---|
WO1991003372A1 true WO1991003372A1 (en) | 1991-03-21 |
Family
ID=23594543
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/US1990/002670 WO1991003372A1 (en) | 1989-09-05 | 1990-05-11 | Variable thickness foam plank |
Country Status (2)
Country | Link |
---|---|
US (1) | US5066531A (en) |
WO (1) | WO1991003372A1 (en) |
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WO1998048962A2 (en) * | 1997-04-25 | 1998-11-05 | Brunswick Corporation | Thermoplastic multi-layer composite structure |
US6218023B1 (en) | 1997-04-21 | 2001-04-17 | Montell North America, Inc. | Co-extruded laminate comprising at least one propylene graft copolymer layer |
US6306518B1 (en) | 1999-05-19 | 2001-10-23 | Montell Technology Company Bv | High surface gloss, co-extruded sheets from propylene polymer materials |
US6432512B1 (en) | 2000-02-01 | 2002-08-13 | Sealed Air Corporation (Us) | Foam plank laminate |
US6489019B1 (en) | 1999-05-19 | 2002-12-03 | Basell Poliolefine Italia S.P.A. | High surface gloss, co-extruded sheets from olefin polymer materials |
DE10214055A1 (en) * | 2002-03-25 | 2003-12-11 | Fraunhofer Ges Forschung | Component built up of layers, e.g. for three-dimensional models, includes interior cavities filled with hardened material to bond layers |
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Cited By (13)
Publication number | Priority date | Publication date | Assignee | Title |
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EP0611643A1 (en) * | 1993-02-17 | 1994-08-24 | 2H KUNSTSTOFF GmbH | Method for the manufacture of punctuel or spot welded joints of at least two layers of thermoplastic material which are close together or adjacent in area of the weld |
US6218023B1 (en) | 1997-04-21 | 2001-04-17 | Montell North America, Inc. | Co-extruded laminate comprising at least one propylene graft copolymer layer |
WO1998048962A2 (en) * | 1997-04-25 | 1998-11-05 | Brunswick Corporation | Thermoplastic multi-layer composite structure |
WO1998048962A3 (en) * | 1997-04-25 | 1999-01-28 | Brunswick Corp | Thermoplastic multi-layer composite structure |
US6489019B1 (en) | 1999-05-19 | 2002-12-03 | Basell Poliolefine Italia S.P.A. | High surface gloss, co-extruded sheets from olefin polymer materials |
US6306518B1 (en) | 1999-05-19 | 2001-10-23 | Montell Technology Company Bv | High surface gloss, co-extruded sheets from propylene polymer materials |
US6432512B1 (en) | 2000-02-01 | 2002-08-13 | Sealed Air Corporation (Us) | Foam plank laminate |
DE10214055A1 (en) * | 2002-03-25 | 2003-12-11 | Fraunhofer Ges Forschung | Component built up of layers, e.g. for three-dimensional models, includes interior cavities filled with hardened material to bond layers |
DE10214055B4 (en) * | 2002-03-25 | 2008-10-30 | Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. | Component with interconnected plate-shaped elements and a method for their preparation |
WO2008000251A1 (en) * | 2006-06-29 | 2008-01-03 | Friedrich Priehs | A method for the production of a cable extruded from a foamable material, the extrusion device for carrying out this method, and the foamed product |
WO2013144130A1 (en) * | 2012-03-26 | 2013-10-03 | Airex Ag | Structural element and method for the production thereof |
CN104203559A (en) * | 2012-03-26 | 2014-12-10 | 艾雷克斯有限公司 | Structural element and method for producing the same |
US9533468B2 (en) | 2012-03-26 | 2017-01-03 | Airex Ag | Structural element and method for the production thereof |
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