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CN101815833A - 不使用粘合剂的硬质可再循环夹芯式聚合物板的生产方法和装置以及所生产的板 - Google Patents

不使用粘合剂的硬质可再循环夹芯式聚合物板的生产方法和装置以及所生产的板 Download PDF

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Publication number
CN101815833A
CN101815833A CN200880100590A CN200880100590A CN101815833A CN 101815833 A CN101815833 A CN 101815833A CN 200880100590 A CN200880100590 A CN 200880100590A CN 200880100590 A CN200880100590 A CN 200880100590A CN 101815833 A CN101815833 A CN 101815833A
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CN
China
Prior art keywords
production line
top layer
circulation
structure top
plate
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Pending
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CN200880100590A
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English (en)
Inventor
埃托尔·费边·马利埃兹库莱纳
马塞洛·德·索萨·派斯·安图尼斯
何塞·伊格纳西奥·维拉斯科·派莱罗
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Ulma CyE S Coop
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Ulma CyE S Coop
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Publication of CN101815833A publication Critical patent/CN101815833A/zh
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    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04G—SCAFFOLDING; FORMS; SHUTTERING; BUILDING IMPLEMENTS OR AIDS, OR THEIR USE; HANDLING BUILDING MATERIALS ON THE SITE; REPAIRING, BREAKING-UP OR OTHER WORK ON EXISTING BUILDINGS
    • E04G9/00—Forming or shuttering elements for general use
    • E04G9/02—Forming boards or similar elements
    • E04G9/05—Forming boards or similar elements the form surface being of plastics
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    • B29C44/20—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of indefinite length
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Abstract

本发明描述了硬质可循环夹芯聚合物板优选聚丙烯基板的生产方法和装置以及所获得的板，其包括三条生产线，在其中之一生产线中，通过挤压生产出聚丙烯基泡沫芯(生产线A)；结构表层在第二条生产线中生产(生产线B)，该表层由用木纤维增强的聚丙烯基薄层形成，在该薄层上施加了用玻璃纤维增强的同样的聚丙烯基表面覆盖层；在第三条生产线中，通过热和压力，在生产线B中生产的结构表层被粘着至生产线A中生产的泡沫芯。所生产的夹芯板具有7mm与40mm之间的厚度、400-700kg/m3的总密度和5-10GPa的弹性模量。

Description

不使用粘合剂的硬质可再循环夹芯式聚合物板的生产方法和装置以及所生产的板
技术领域
本发明涉及用于建筑领域中的不使用粘合剂的硬质可再循环夹芯式板的生产和装配装置，所述板由泡沫硬质内芯和结构表层形成，两者在性质上都是聚合物。
该装置被供应一种高分子材料新配方，所述高分子材料混合和熔化后，通过挤压而起泡，形成具有最佳机械性能、防潮性和包括100kg/m3与500kg/m3之间的对比密度的硬芯(典型特定弹性模量(specificelastic modulus)为1.5Gpa cm3/g)。
所述结构表层在不使用粘合剂的情况下被装配在由挤压获得的芯上，形成硬质且可再循环的夹芯板，用于构件应用，特别用于建筑领域。
背景技术
在建筑领域木质模板面板的使用一直是非常广泛的，这些板提供很多优点，包括提供良好的机械特征和受钉性方面的优点。然后，由于开展它们的活动所处的环境，木质模板面板寿命短，这是因为它们经常暴露于水、湿气、耐磨材料(水泥、石灰、混凝土等)，这些都缩短它们的使用寿命。
另外，一旦变质，它们必须被移动，并且修复和再循环它们的可能性是复杂的而且在任何情况下都受到限制。
涉及从森林树木生产数百万平方米的模板的生态影响也是很显著的，这正是所有从如木材一样稀少的资产中制造的产品所发生的情况。
为了板的耐用性的目的，结合木材和塑料材料的模板面板已经开发了很长时间。这种类型的板被描述于专利DE 19611413、DE 19611382和EP 1426525中。木质板通常补充有塑料材料的棱和边缘，它们适当地装配或固定到木芯，一定程度上防止板在运输、掉落和敲击时变质。
同样，已经研究和开发了仅由高分子材料、再循环橡胶或各种塑料材料的组合形成的板的生产方法。该技术通常试图满足双重目的，一方面，处理由汽车工业产生的大量塑料废物，以及通过其再循环用于生产建筑用板而寻求这类废物的应用。
从再循环材料中生产板的方法描述于专利WO 2004/111368中，其允许基于来自粉碎轮胎的塑料和橡胶制造复合板。得到的芯，并使结构表层加到其上，以形成模板。除不具有模板面板要求的良好的机械和受钉性特征外，通过这种方法制造的板非常密实并且难以再循环。
夹层式分离结构板已经被使用很长时间，如专利US3,305,991、US3,555,131、US 3,838,241和US 4,120,330中所述。这些专利开发了形成热焊接泡沫的方法，在模具内制备泡沫。有许多专利涉及使用物理型发泡剂通过连续直接挤压进行结构校准的发泡方法，诸如夹芯板的芯。然而，不考虑所使用的材料的配方，所述方法中的许多限于制造泡沫板必需的机器。
此外，在现有技术状态已经被开发出基于聚合塑料材料例如聚乙烯(PE)或聚丙烯(PP)的板。相对于PE，PP具有几种优点，例如其机械性能，PP的弯曲弹性模量为1.5Gpa，PE为200Mpa。然而，PP发泡一直由于其在熔化状态下的低拉伸粘度和剪切粘度(熔体强度)而受到阻碍。这种限制——与PP的化学性质相关，意味着后者在正常的条件下不具有足够的熔体强度以承受在发泡过程中气泡的膨胀，这引起整体蜂窝状结构的坍塌并且严重限制具有对比密度(＜200kg/m3)的泡沫的产生。通过不同化学方法使用催化的的PP交联方法随后被考虑，这提供了具有较高熔体强度的聚合物。然而，在这种情况下，由于聚合物的交联结构，即使轻泡沫(＜200kg/m3)被产生，其可再循环性和其循环是及其困难的过程。
在其它情况下，已经开发了用于生产夹层材料的装置，该夹层材料使用柔性聚氨酯或聚烯烃基柔性泡沫芯(LDPE、EVA......)，通过粘合剂与表层附着，用于鞋类、运动器材等等。一个例子是专利EP 1745909A2。
专利DE 2041892描述用于制造不可再循环模板的装置，其考虑了通过使用粘合剂使用附着至表层的聚氨酯泡沫芯的可能性。
然而，在现有技术状态，对提供建筑用板仍存在需要，其专有地由高度耐用的易于修复的高分子材料形成，当所述高分子材料的使用寿命结束时，其可以被再循环并且甚至被作为形成新的建筑用硬质可再循环板的原材料使用，因此形成一个保护环境且允许稀有自然原料的大量节约的循环。
在这种意义上，本发明的发明人已经开发出配方以及生产和装配线，其允许生产硬质夹层式结构板以应用于建筑，所述板具有作为模板面板的最佳特性，除了由于粘合剂不存在而完全可再循环之外，还突出其高硬度、对比密度和长期耐用性。
发明目的
本发明的目的是生产和装配硬质可再循环夹芯式聚合物板的装置，其中所述板由泡沫芯形成，其中所述泡沫材料针对所提议的目的提供了良好的机械特性、良好的受钉性和减小的密度。
用于生产由泡沫芯和两层聚合物结构表层形成的夹芯式板的方法也是本发明的目的。
所述泡沫芯和结构表层也是本发明的目的。
所生产的实际硬质可再循环夹芯式板同样是本发明的目的。
发明内容
用于生产硬质可再循环夹芯式板的装置被分为三条明确定义的生产线：
—生产线A，其中泡沫芯被制造。
—生产线B，其中不使用粘合剂，发生结构表层的层压和装配。
—生产线C，其中结构表层被附着至泡沫芯，并且实施夹芯式板形状和尺寸的最后加工。
生产线A被分为四个区域，具体为：
a)挤压区，用于挤压板的泡沫芯
b)校准区，用于校准泡沫芯
c)冷却区，用于冷却泡沫芯
d)牵引区，用于取出泡沫芯。
挤出机是必需的机器组件，并且材料在其中将被制备用于下一步骤，例如校准步骤、冷却步骤和牵引步骤以制造泡沫芯。
所使用的挤出机由密封于线状腔内的单螺杆形成，在其内部开发了如下所述的四个基本功能：
—输送部分固态/软化状态的进料。
—熔化进料和对其进行挤压。
—用气体充气聚合物混合物。
—匀化和计量进入到挤压头中的混合物，其中所述混合物被挤压，采用具有可变密度和厚度的片形，形成所述夹芯板的泡沫芯。
所述泡沫芯由包含原始的或循环的线型均聚物聚丙烯(线型-PP)的高分子材料和高熔体强度支化聚丙烯(支化-PP)及其它添加剂的混合物制造，其可包括润滑剂以改进材料和纳米和/或微米型增强材料(可变长度的玻璃纤维)的加工，目的是调节泡沫芯的热和机械性能。
使用的发泡剂属于物理/化学类型。物理发泡剂被引入挤出机中并且在超临界条件下与熔融体混合，由此确保其最大熔解性。已开发的技术允许调节挤出机中的压力条件和气体输入流量条件，以及所引入的气体类型(CO2、N2、正丁烷、正庚烷或它们的混合物)。
线型聚丙烯和支化聚丙烯百分比在配方中的修改，以及添加剂和亲有机物质陶瓷颗粒及矿物填料的掺入，允许依照每种情况的需要，生产具有不同特征的硬质可再循环板。
根据合适的配方，所述方法中涉及的材料以小球形式被预先混合，以生产合适的板。如此混合的这种材料被引入被称为重量型进料斗的重力进料斗中，其负责将材料存放在挤出机的进料口中，该口被冷却以阻止可能形成的塑料塞，由于实际颗粒彼此之间粘着或由于在实际进料斗或进料口上的颗粒粘着，可能产生塑料塞。
材料的供应与挤出机螺杆的转速成比例，根据处理的原料的类型，该挤出机具有可变的最大生产流量。
根据挤出机要实现的功能，通过改变螺杆螺距、改变腔的直径或螺杆的直径等，螺杆的设计可以被调整。
螺杆最初被设计为引起在熔融状态中塑料原料被压缩，随后其通到减压或充气区，在那里气体在压力下通过喷嘴被注入，其加入熔融的塑料原料中。接下来，螺杆具有第三步骤，通过该步骤，并且一旦熔融塑料与在压力下引入的气体混合，该熔融塑料和气体物质又被压缩，在随后步骤中一起进行产物的匀化和混合，其中确保机器内部的产物不膨胀。
螺杆的最大转速是可变的并且取决于所处理的材料，因为如果材料用无机型填料增强，那么通过电机驱动螺杆而展开的努力可能显著增加，因此极大限制了最大转速。
电阻以及不同区域的冷却风扇连接至挤出机套筒的不同区域，贯穿整个挤出机维持稳定的温度。
在螺杆之后有一个齿轮泵，随后是挤压头。齿轮泵允许调节生产，消除在挤压头内的可能的压力脉动。
挤压头具有平面几何形状，适合平面板的生产，其内部被设计为实现熔融聚合物与发泡剂的混合物的优良匀化，阻止在混合物到达挤压头唇部(lip)之前在挤出机内减压区的存在，所述减压区是准确地位于挤压头末端的区域。
减压通常与挤出机圆筒的截面或挤压头截面的增加相关，导致完全或部分的气泡成长在熔融聚合物体内分散。由于牵引作用，在机器内的这种完全或部分的发泡通常引起蜂窝的破裂和坍塌，因为在这些区域中，混合物处于较高温度并且通常不具有足以承受气泡生长和其牵引的熔体强度。
本发明提议的最相关的挤压头特征是其具有适用于本发明所述方法的T型分配通道，包括细分成截面减小的其它通道的分配通道，和更进一步包括节流条(restricting bar)和灵活开启唇部(opening lip)。所述挤压头具有与其耦合的不同电阻，确保穿越挤压头的全部材料被加热。
具有鱼尾型或甚至头盔型的T型分配通道的设计不适合使用的材料，因为在膨胀过程的第一步骤它们不允许合适的控制。与使用这些类型的设计相关的主要问题在于在三种情况中的流动分配将涉及相当大的所处理材料的减压，这是相对于将挤出机连接至挤压头的适配器，分配通道的截面增加。在具有溶解气体的材料的情况中，它可导致在挤压头内完全或部分的气泡的生长。
材料在挤压头内部的完全或部分膨胀的这些条件连同高温，相对于在唇部其出口处所证实的条件，将导致低熔体强度，所述强度经常与材料承受整体蜂窝结构的能力相关，因为蜂窝所产生的变形或者甚至破裂可能发生在材料牵引过程中。
除了不允许适当地控制整个发泡过程，由于蜂窝的聚结，这种情况可能产生具有不合适的蜂窝形态的泡沫片，这与材料的低熔体强度、蜂窝的变形和破裂相关，并因此产生具有高密度(＞400kg/m3)和有限性能的泡沫，尤其是关于泡沫板的硬度和韧度。
由于材料流动分配通道的截面经过挤压唇部在其出口处逐渐减小，本发明的挤压头是分配式多通道类型，这确保熔融材料的压力逐渐增加，并因此通过在挤压头唇部出口处确切的降压，使得在熔融体内的溶解气体的膨胀或发泡过程的第一步得到控制。
唇部连同位于其前面的节流条是可调节的，并允许控制对熔融混合物施加的压力，而且因此调节成品片材的密度以及发泡剂的量。
尽管冷却和最终稳定泡沫片的过程是基本通过真空接触校准器的作用完成的，但是这种挤压头设计——因为考虑到材料流动分配具有新颖性，确保具有溶解气体或多种气体的熔融聚合物体——其通过挤出机的作用预先被匀化，不经发泡到达其出口，即唇部区域。
在挤压头唇部出口处准确实现的受控发泡确保片材在板的宽度和厚度上均具有统一的蜂窝尺寸分配，以及通过板的蜂窝结构的接触校准的作用具有适当的稳定性。
校准系统不仅用于调整泡沫的最终膨胀率，也用于调整泡沫板的表面外观。最终不是很粗糙的泡沫板表面，在具有或没有粘合剂的帮助下，对于结构表层的合适装配是必要的。所述系统由三个、优选四个具有应用真空能力的校准平面校准器组成，第一校准器，连同使用的起泡剂部分一起，是调节所形成的泡沫板或芯的最终厚度的校准器，而另外两个优选三个校准器调整最终的表面外观。
所述板通过在浴中与冷却水直接接触被冷却。
泡沫板的牵引和收集系统允许调整板的轴向定位，并因此针对泡沫芯生产过程调整板两个方向的机械性能。
聚合物泡沫芯可具有包括100kg/m3与500kg/m3之间的密度，这取决于夹芯板所需的最终密度和特定弹性模量，即，相对于材料的密度，＞1.2GPa cm3/g，优选地在1.4GPa cm3/g和1.5GPa cm3/g之间，并且剪切模量在40MPa和100MPa之间。
所述芯也必须具有如下尺寸以被进料到具有结构表层的热熔系统，即，宽度在250mm和2400mm之间，优选地在1000mm和1400mm之间，厚度在5mm和30mm之间，和可变的长度。
泡沫芯被制造后，通过结构表层的热熔它们被送入装配线C，结构表层又在生产线B中被制造，包括：
e)层压系统，通过挤出连续生产具有天然纤维的聚丙烯基(PP)薄层，形成表面涂层。
f)熔融和压光系统，其将聚丙烯基结构薄层或用玻璃纤维加强的层附着至在e)中制造的薄层。
结构表层由结构层和覆盖层形成。当表层被附着至此时结构层与芯接触。
优选聚丙烯基结构层用玻璃纤维网络增强，玻璃纤维的百分比在30％至60％之间，且优选为重量的60％。该层的厚度为0.2-0.8mm。
这种网络可以具有轴向和纵向方向比例为1∶1、2∶1、3∶1和4∶1的长纤维。取决于所述网络，弹性模量可以在1∶1型的13Gpa与4∶1型的22GPa之间变化。
表面覆盖层通过连续挤出具有天然纤维如木纤维的聚丙烯基薄层形成，所述天然纤维含量占30wt％和50wt％之间。这些薄层具有包括0.8mm和1.8mm之间的厚度，优选1.5mm，且宽度取决于所述夹芯板寻求的最终宽度。
在另一可能的实施方式中，覆盖层是由两层依次形成的共挤出薄层，一层基于聚烯烃和有机填料的混合物，例如纤维素纤维或颗粒，以及第二聚烯烃基层，其具亲有机物质陶瓷颗粒和/或矿物填料，优选由碳酸盐或滑石形成。所述有机和矿物填料形成各自混合物的一部分，比例占40wt％和60wt％之间。
所述两层的厚度根据板需要的最终特征进行调整。
由此形成的结构表层具有的8至15GPa的总弹性模量，这取决于在结构表层中存在的玻璃纤维的网络类型和覆盖层中存在的天然纤维的百分比。
在一个简化的实施方式中，结构表层可以由用按重量计50-55％的短玻璃纤维增强的单独聚丙烯基挤出薄层形成，其弹性模量为10-13GPa。
覆盖薄层或层压系统是由共旋转直径140mm的双螺杆挤出机形成的，制造出具有聚丙烯基成分的薄层，其中天然纤维通常为木纤维的百分比占30wt％和50wt％之间。这些薄层具有从0.8mm和1.8mm之间的厚度，优选为1.5mm，且取决于所述夹芯板寻求的最终宽度，宽度250mm和2400mm之间。
该系统由三个滚筒形成的压光装置组成，负责冷却挤出薄层和确定其最终厚度。该系统同样由进料机制组成，用于进料来自卷筒的结构薄板或层，以使其连同挤出薄层一起压层。结构层性质上是用机织玻璃纤维增强的聚合物。
取决于在表面覆盖层中存在的纤维的网络类型，由此获得的结构表层具有8Gpa与15GPa之间的总弹性模量。
因此获得的结构表层通过融化以及在生产线A中制造的泡沫芯两面上的压力而被粘着。
结构表层与芯的装配发生在生产线C，由下述组成：
g)进料聚合物泡沫芯的系统。
h)进料将被装配到芯的结构表层的系统。
i)通过热熔将结构表层附着至芯的连接系统。
j)收集连续制造的板的牵引系统。
k)纵向和横向切割所述板的系统。
l)堆集板的堆集系统(palletizing system)。
用于进料在生产线A中制造的轻质聚合物芯的系统是半自动化系统，其负责将所述芯进料到用于将所述芯附着至先前在生产线B中生产的结构表层的单元，所述芯具有250mm和2400mm之间的宽度、1200mm和3500mm之间的长度和5mm和35mm之间的厚度的尺寸，通常芯为1200mm宽、2700mm长和15mm厚。
用于进料结构表层的系统连续地在芯上供应各上表层和下表层。这些表层来自于卷筒，其通过导辊和张力辊装配被送至连接系统。
用于将覆盖的结构表层附着至芯的连接系统由双红外(IR)加热系统以及巩固连接的压力辊系统组成，所述双红外加热系统同时作用于芯和表层的面上。
其同样由通过水冷却的校准系统组成，这确保夹芯的厚度的一致，并根据寻求的最终厚度起作用。其更进一步的具有通过用水喷射的冷却浴。
收集系统由牵引辊的装配组成。
用于切割所述板的系统由自动圆锯组成，其中的两个作用于板的边缘，连续地切割以获得需要的最终宽度，第三个锯负责夹芯板的横向切割以获得需要长度的板。
装夹系统由生产用于夹芯板随后分配的夹芯板收集和封装系统组成。
从前述装置制造硬质可再循环夹芯聚合物板的方法由下述步骤组成：
a)在生产线A中，根据下面步骤制造泡沫芯：
-在挤出机中使先前熔化的聚合体与增强材料和其它添加剂接触，和使混合物与发泡剂均匀化；
-在挤压头的出口处获得泡沫芯；
-校准和冷却泡沫芯；
-取出泡沫芯；
b)在另一条平行生产线——生产线B中，以如下步骤获得结构表层：
-通过挤压获得用天然纤维优选木纤维增强的聚丙烯基薄板；
-将在轴向和纵向方向安置的、优选用玻璃纤维增强的聚丙烯基结构薄板或层，通过压光与挤出薄板相连。
c)在另一条生产线——生产线C中，将生产线B中获得的结构表层与生产线A中获得的轻质泡沫芯相连，根据三个步骤：
-以匀速将泡沫芯和结构表层送至红外(IR)加热器系统，以使芯和结构表层的表面熔化；
-表面经加热变软，通过驱动一连串压力辊将表层与芯连接，使表层附着至芯；
-通过具有应用真空能力以及具有内部冷却回路的接触校准器，消除可能留在芯的表层之间的可能的空气气泡。
附图简述
为了完成正在进行的描述和帮助更好理解本发明特征的目的，一组附图被附于本发明的说明书作为其组成部分，其中下述以说明性和非限定性特征进行显示：
图1描述所述夹芯板的泡沫层的生产线A的图示。
图2描述螺杆和泵送与冷却区域的设计图示。
图3详细地描述充气区域和各个进气口。
图4描述用于生产本发明泡沫板的多通道挤压头的图示。
图5描述所述装置的生产线B，其中结构表层被制造。
图6描述所述装置的生产线C，其中结构表层被物理连接至泡沫芯，且板被纵向和横向切割以调整它们到需要的尺寸。
图7展示在生产线A中制造的泡沫芯的透视图细节。
图8描述在生产线B中制造的结构表层的细节，其中玻璃纤维的轴向和横向放置可以被看见。
图9展示在生产线C中被制造的夹芯板的透视图细节。
具体实施方式
图1描述夹芯板的泡沫芯(5)生产线的图示，展示了机器所划分的四个区域，它们为：
-挤压区域(1)
-校准区域(2)
-冷却区域(3)
-牵引区域(4)
挤压区域由封入线状腔(7)中的单螺杆(6)形成，在该线状腔内执行三个基本功能，它们是：
-输送部分固态或软化状态的进料
-熔化进料和对其挤压
-混合、均匀化和计量，进入形成平面挤压头的成型喷嘴中，以生产具有不同厚度和密度的泡沫片。
根据适合于制造合适板的配方，所述方法中涉及的材料是高分子材料，且它包括含有高熔体强度聚合物和线型均聚物聚丙烯的聚合体，其以小球形式预先混合。这种如此混合的材料被引入被称为重量型进料斗的重力进料斗(8)中，其负责将材料存放在挤出机的进料口中，该口被冷却以阻止可能形成的塑料塞，由于实际颗粒彼此之间粘着或由于在实际进料斗或进料口上的颗粒粘着，可能产生塑料塞。
通过穿过其中的引入电阻(9)，设置有螺杆(6)的线状腔(7)被加热，这样塑料材料最初被软化和熔化，然后通过维持这种加热，贯穿整个螺杆腔内的塑料材料被熔化。
在螺杆(6)和其线状腔(7)之后，存在齿轮泵(10)，并且其后是挤压头(11)。该齿轮泵允许调节生产，消除在挤压头(11)内的可能的压力脉动。
气体被从加压瓶(12)中被引入挤出机，这确保超临界流体状态并因此确保与熔融塑料体的最大溶解性。该机器优选地有四个进气口(13)，位于沿线状腔的充气区域的不同位置，这使得能够调整与熔融材料体的混合水平。
校准区域(2)不仅用于调整泡沫的最终膨胀率，而且用于调整泡沫板的表面外观。最终不是很粗糙的泡沫板表面，在具有或没有粘合剂的帮助下，对于所述结构表层的合适装配是必要的。所述系统由优选四个具有应用真空能力的校准平面校准器(14)、(15)、(16)和(17)组成，第一校准器(14)，即最靠近挤压头(11)的校准器，连同使用的起泡剂部分一起，是调节所形成的泡沫板的最终厚度的校准器，而另外其它三个校准器(15)、(16)和(17)调整最终的表面外观。
接下来，所述板传到冷却槽(3)，在那里其通过与冷却水直接接触被冷却。然后传至板牵引和收集区域(4)，该区域允许调整板的轴向方向，以及因此针对泡沫芯生产过程调整在两个平面方向的机械性能。
图2描述螺杆和泵送及冷却区域的设计图示。该图展示螺杆(6)和线状腔(7)，螺杆以及用于引入气体的喷嘴(13)位于线状腔中。
为了提供所述螺杆的实际实施方式的描述，其测量将以螺杆长度或每个区域的长度相对于螺杆直径的比例给出。
因此以特定的方式，以(25)描绘的螺杆长度在螺杆直径的36与42倍的范围内，其中压缩比包括2和3之间，而关于螺杆区域之后的泵送及冷却区域(24)，其测量在螺杆直径的10与14倍之间的范围内，且其在聚合物和气体的混合物被泵送和冷却的区域中，该区域通过齿轮泵(10)的作用对消除产生于挤压头中的可能的压力脉动是必要的，并且对于逐渐冷却已处理的材料体是必要的。
在由螺杆(6)的长度界定的区域(25)中，腔被分为四个区域，它们是：
-进料区(20)
-压缩区(21)
-充气区(22)
-计量区(23)
进料区(20)负责输送来自进料斗(8)的软化材料，而且可以具有近似在6倍与10倍于螺杆直径之间的长度范围。
压缩区(21)，其中材料被熔化，具有的长度在6倍与10倍于螺杆直径之间，取决于处理速度，其中一段是双螺纹。
充气区(22)是挤出机线状腔(7)的不同进气口(13)所处的区域。该区域的长度同样在10倍与14倍于螺杆直径之间变化，并具有专用混合区域，用来混合熔融材料与借助材料输送区加入的分散气体或多种气体。
最后，计量区(23)是熔融材料与气体混合的区域，且其具有4倍与8倍于螺杆直径之间的长度。
图3展示充气区(22)和前面提及的压缩区(21)和混合区(23)如何置于其两侧的放大细节图。除了用于引入气体的喷嘴(13)，该图突出了螺杆(6)如何采用几种特性，尤其是采用具有较小直径的轴的螺杆，由此就线形腔(7)而言产生较大空间，这便于气体与气体引入其中的塑料物质的混合；且其次突出了如何存在专用混合区域(30)，用来将熔融材料与借助材料输送区(31)加入的分散气体或多种气体混合。
图4描述了本发明的泡沫芯生产中使用的多通道挤压头(11)的图示。本发明所提议的挤压头的最相关特征在于：其具有适应于本发明所述方法的T型分配通道(40)，其包括以截面减小的其它通道(41)细分的分配通道，且进一步包括节流条(42)和灵活开启唇部(43)。挤压头(11)具有与其耦合的不同电阻，这确保穿过其的全部材料被加热。
由于材料流动分配通道部分在其出口处经过挤压唇部(43)的截面逐渐减小，本发明的挤压头属于分配多通道，这确保熔融材料的压力逐渐增加，并因此通过在挤压头唇部出口处确切的降压，使得在熔融体内的溶解气体的膨胀或发泡过程的第一步得到控制。
唇部连同位于其前面的节流条(42)是可调节的，并允许控制对熔融混合物施加的压力，而且因此调节成品片材的密度以及发泡剂的量。
尽管冷却和最终稳定泡沫片的过程是基本通过真空接触校准器的作用完成的，但是这种挤压头设计——因为考虑到材料流动分配而具有新颖性，确保具有溶解气体或多种气体的熔融聚合体——其通过挤出机的作用预先被匀化，不经发泡到达其出口，即唇部区域。
在挤压头唇部(43)出口处准确实现的受控发泡确保片材在板的宽度和厚度上均具有统一的蜂窝尺寸分配，以及通过板的蜂窝结构的接触校准的作用具有适当的稳定性。
生产线C被进料在生产线A中制造的泡沫片。将被粘着于泡沫芯的结构表层在生产线B中被平行生产。
展示生产线B的图5，显示了结构表层的生产系统，所述结构表层随后将在连接系统中在无粘合剂的情况下被附着至芯的两面以生产所定义的夹芯板。首先，其由直径140mm和长5000mm的双螺杆挤出机(50)组成，其中通过挤压连续生产用天然纤维特别是木纤维增强的聚丙烯基薄层(51)，纤维的百分比在30wt％和50wt％之间。这种薄层具有0.8-1.8mm的典型厚度，优选为1.5mm，以及250mm-2400mm的宽度。其次，厚度为0.2-0.8mm的结构层(52)——用玻璃纤维(30-60％的玻璃纤维)、优选具有不同网格的玻璃纤维增强的聚丙烯基薄层，通过卷筒被送入系统中。这种结构层(52)通过红外系统(53)，该红外系统局部熔化聚合物基体，与由三个滚筒形成的压光系统(54)一起，协助将覆盖薄层(52)附着至在挤出机(50)中生产的、用天然纤维增强的、仍然软化的聚丙烯基薄层(51)的表面上。该三滚筒系统进一步负责冷却具有涂面的挤出薄层并确立涂面薄层的最终厚度。
由此制造的结构表层(55)由大约0.8-1.8mm厚、用30-50wt％天然纤维增强的聚丙烯基薄层的覆盖层(51)和大约0.2-0.8mm用30-60％纤维优选玻璃纤维增强的聚丙烯基薄层的结构层(52)组成。
特别地，取决于夹芯板的最终要求，结构层(52)可以具有与纤维的方向性相关的不同的网格。其因此可具有1∶1、2∶1、3∶1和4∶1的网格，其为在一个方向定向的纤维数量与在另一个方向定向的纤维数量之间的比例(因此，对于在轴向方向定向的每个纤维，1∶1网格将具有一个横向定向的纤维)，弹性模量在1∶1网格的13GPa与4∶1网格的22GPa之间变化。
在另一个可能的实施方式中，覆盖层是由两层依次形成的共挤出薄层，一层基于聚烯烃和有机填料的混合物，优选为纤维素性质的，而第二基于聚烯烃的层含有矿物填料。
图6展示通过热熔已覆层的结构表层至轻质聚合物芯的连接生产线。该生产线被不连续地(来自储存的轻质聚合物芯)或连续地供应通过挤压由物理起泡方法制造的聚丙烯基泡沫片。来自两个卷筒(60)的结构表层(55)同样被引入系统中，因此表层被叠加在泡沫芯(5)的两个正面上，在轻质聚合物泡沫芯(5)的两侧上设置各表层是可能的。
随着覆层结构表层更接近轻质芯的两侧，它们经过红外(IR)系统(61)，该红外系统通过局部熔化聚合物起作用，其在芯的表面上同时起作用，伴随着排列在芯两侧的压力辊(62)(每侧三个)立即开动，这使得在芯与两个结构表层之间能够良好附着。随后具有应用真空的能力且具有含水内部冷却回路的平面接触校准器(63)，允许消除可能已经被截留在表层和芯焊接处的空气气泡，并最终形成其最终厚度。
图9展示在生产线C中制造的夹芯板(64)，其必须具有7mm到40mm之间的芯厚度(64a)和1.2-2.2mm厚度的表层(64b)。总密度将在400-700kg/m3之间，弹性模量在5-10GPa之间。

Claims (26)

1.一种不使用粘合剂而生产硬质可循环夹芯式聚丙烯基板的装置，包括：
a)生产线(线A)，其通过挤压方法，生产混合有亲有机物质陶瓷颗粒的硬质聚合物基泡沫芯，所述泡沫芯具有100kg/m3与500kg/m3之间的密度；
b)生产线(生产线B)，用于生产被称为结构表层的薄层，所述薄层由用玻璃纤维网格增强的聚合物优选聚丙烯基的结构层和含有天然纤维、亲有机物质陶瓷颗粒和/或矿物填料的挤出聚丙烯基表面覆盖层依次形成；
c)生产线(生产线C)，用于在无粘合剂的情况下将b)中定义的所述结构表层装配至在a)中定义的硬质泡沫芯中，所述表层的所述结构层是与所述硬质泡沫芯接触的层。
2.根据权利要求1所述的用于生产硬质可循环夹芯式聚合物板的装置，其特征在于，生产线A的单螺杆挤出机的螺杆(6)的进料区(20)是用于输送来自于进料斗的软化材料的输送区，其具有6至10倍于螺杆直径之间的长度。
3.根据权利要求1所述的用于生产硬质可循环夹芯式聚合物板的装置，其特征在于，生产线A的单螺杆挤出机的螺杆(6)的压缩区(21)是用于熔化来自于进料区的材料的熔化区，其具有6至10倍于螺杆直径之间的长度。
4.根据权利要求1所述的用于生产硬质可循环夹芯式聚合物板的装置，其特征在于，生产线A的单螺杆挤出机的螺杆(6)的充气区(22)包含不同的进气口(13)并具有材料的附加混合和输送区，所述充气区具有10至14倍于螺杆直径之间的长度。
5.根据权利要求1所述的用于生产硬质可循环夹芯式聚合物板的装置，其特征在于，生产线A的单螺杆挤出机的螺杆(6)的计量区(23)具有4至8倍于螺杆直径之间的长度，熔化材料在该计量区内被混合。
6.根据权利要求1所述的用于生产硬质可循环夹芯式聚合物板的装置，其特征在于，生产线A的单螺杆挤出机的挤压头(11)是多通道头。
7.根据权利要求6所述的用于生产硬质可循环夹芯式聚合物板的装置，其特征在于，在所述挤压头中的材料分配通道是T型的，所述通道又被分成截面逐渐减小的其它多重通道。
8.根据权利要求7所述的用于生产硬质可循环夹芯式聚合物板的装置，其特征在于，分配头的出口包括节流条和灵活开启唇端，所述节流条和灵活开启唇端调节对混合物施加的压力并因此调节最终片的密度。
9.根据权利要求1所述的用于生产硬质可循环夹芯式聚合物板的装置，其特征在于生产线A的单螺杆挤出机的校准区(2)包括调节所述板的表面外观的机构，所述机构包括具有应用真空的能力的校准平面校准器。
10.根据权利要求1和9所述的用于生产硬质可循环夹芯式聚合物板的装置，其特征在于，位于挤压头(14)出口处的第一校准器包括调节所述板的最终厚度的机构，而随后的一个或多个校准器包括调节所述板的最终表面外观的机构。
11.根据权利要求1所述的用于生产硬质可循环夹芯式聚合物板的装置，其特征在于，生产线A的单螺杆挤出机的冷却区(3)包括冷却浴，在该冷却浴中冷却水与待被冷却的泡沫板直接接触。
12.根据权利要求1所述的用于生产硬质可循环夹芯式聚合物板的装置，其特征在于，生产线A的单螺杆挤出机的泡沫板(4)的牵引和收集区包括调节所述板的轴向定位及其机械性能的机构。
13.根据权利要求1所述的用于生产硬质可循环夹芯式聚合物板的装置，其特征在于，所述结构表层的生产线(生产线B)由以下组成：
a)层压系统，通过挤出连续生产具有天然纤维的聚合物薄层；
b)软化和压光系统，用于将用玻璃纤维增强的聚合物结构层装配至离开所述挤出机的薄层；
c)滚筒系统，用于确定由挤出薄片和附着至所述挤出薄层的结构层的装配而形成的结构表层的厚度。
14.根据权利要求13所述的用于生产硬质可循环夹芯式聚合物板的装置，其特征在于，所述结构表层(生产线B)的层压系统由以下组成：
d)双螺杆挤出机(50)，其生产用天然纤维优选木纤维增强的聚丙烯基薄层(51)；
e)所述结构层(52)的进料器，其由在轴向和横向排列的玻璃纤维增强的聚丙烯基薄层组成；
f)机构(53)，其用于通过热软化所述结构层(52)，然后通过压光系统(54)借助压力将所述结构层附着至所述薄层(51)。
15.根据权利要求1所述的用于生产硬质可循环夹芯式聚合物板的装置，其特征在于用于将结构表层装配至轻质泡沫芯的装配线(生产线C)由以下组成：
g)系统，用于进料通过在生产线A中挤压而生产的轻质聚合物芯；
h)系统，用于进料先前在生产线B中生产的结构表层；
i)连接系统，用于通过热熔将所述结构表层附着至所述泡沫芯；
j)牵引系统，用于收集连续生产的板；
k)系统，用于纵向和横向切割所述板；
p)堆集系统，用于堆集所生产的板。
16.根据权利要求1所述的用于生产硬质可循环夹芯式聚合物板的装置，其特征在于，泡沫芯(5)和表层(55)经过红外系统(61)以促使聚合物表面软化，然后通过一系列压力辊(62)促使所述表层(55)附着至芯(5)。
17.根据权利要求1和16所述的用于生产硬质可循环夹芯式聚合物板的装置，其中在所述压力辊(62)之后，所形成的夹芯板传至具有真空能力的平面校准器(63)，以消除可能的气泡。
18.一种连续生产硬质聚合物泡沫片的的方法，包括下列步骤：
a)在挤出头中使聚合体和配方的其它成分接触，
b)通过挤压生产泡沫片(5)，使得起泡发生在挤压头的出口处，
c)校准所述泡沫片，
d)冷却和牵引所述泡沫片，
e)在平行生产线(生产线B)中生产结构表层，
f)将泡沫芯(5)和结构表层(55)进料到装配线(生产线C)中，
g)通过热和压力将结构表层(55)附着至泡沫芯(5)，
h)纵向和横向切割所生产的夹芯板以调整它们到需要的尺寸，
i)移出和堆集所述夹芯板。
19.在权利要求1所述的装置中在不使用粘合剂时生产的硬质可循环夹芯式板，其包括：硬质聚合物-陶瓷混合泡沫芯，该泡沫芯优选地基于聚丙烯和亲有机物质陶瓷颗粒和矿物填料，厚度在5mm与35mm之间，特定弹性模量在1.4GPa cm3/g与1.5GPa cm3/g之间，剪切模量在40MPa和100MPa之间；两个结构表层，其中每个层又由两个层形成，用玻璃纤维增强的聚合物优选聚丙烯基的结构层，和用天然纤维增强的聚丙烯基表面覆盖层，在无粘合剂的情况下，通过热熔和压力所述两个结构表层被附着至所述芯。
20.根据权利要求19所述的硬质可循环夹芯板，其中所述结构层是具有交联玻璃纤维的挤出薄层，玻璃纤维的百分比在30％和60％之间，该层的厚度为0.2mm至0.8mm。
21.根据权利要求20所述的硬质可循环夹芯板，其特征在于，所述结构层的长玻璃纤维以1∶1、1∶2、1∶3和1∶4的轴向纤维与横向纤维比率被轴向和横向布置。
22.根据权利要求19所述的硬质可循环夹芯板，其特征在于，所述表面覆盖层是具有木纤维或其它天然纤维的挤出聚丙烯基薄层，纤维含量按重量计为30wt％至50wt％，厚度为0.8mm至1.8mm。
23.根据权利要求19所述的硬质可循环夹芯板，其特征在于，所述表层的所述结构层具有13GPa与22GPa之间的弹性模量(分别针对1∶1和1∶4网格)，这取决于所述玻璃纤维的网格。
24.根据权利要求19所述的硬质可循环夹芯板，其特征在于，由所述结构层和所述表面覆盖层形成的所述结构表层具有8GPa至15GPa的总弹性模量，这取决于在所述结构层中存在的玻璃纤维的网格以及在覆盖层中存在的天然纤维的百分比。
25.根据权利要求19所述的硬质可循环夹芯板，其特征在于，在简化形式中，所述表层由先前挤压的含短玻璃纤维的单独聚丙烯基薄层形成，纤维的重量百分比为50-55％，弹性模量为10-13GPa。
26.根据权利要求19所述的硬质可循环夹芯板，其特征在于，所述夹芯板具有7mm与40mm之间的厚度，表层厚度为1.2mm至2.2mm，总密度为400-700kg/m3以及弹性模量为5GPa至10GPa。
CN200880100590A 2007-07-27 2008-07-24 不使用粘合剂的硬质可再循环夹芯式聚合物板的生产方法和装置以及所生产的板 Pending CN101815833A (zh)

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