Patent Application
20180079167
The present invention relates to a method of adhering multiple polyurethane foam layers together which is applied to stick the multiple polyurethane foam layers successively so as to enhance adhesion and production capacity.
Polyurethane foam (PU foam) layer is made of polyurethane system components comprised of isocyanate component and polyol component, and water and catalyst are added into the polyurethane system components so that the water and the isocyanate component are mixed to produce carbon dioxide by which the polyurethane foam layer is foamed and is applicable for building materials, packaging material, and vibration absorption material, such as mattresses, cushions or insoles.
As shown in
1. The adhesive 4 causes environment damage.
2. The multiple polyurethane foam layers cannot be adhered securely by using the adhesive 4.
3. Due to the multiple polyurethane foam layers have different properties, they foam respectively and then are adhered together, thus reducing production efficiency.
4. After foaming the multiple polyurethane foam layers, the adhesive 4 is cladded on the multiple polyurethane foam layers, thereby having troublesome production.
5. After foaming the multiple polyurethane foam layers, the adhesive 4 is cladded on the multiple polyurethane foam layers so that the multiple polyurethane foam layers adheres together, but such an adhering method will limit production sizes of the multiple polyurethane foam layers.
The present invention has arisen to mitigate and/or obviate the afore-described disadvantages.
The primary objective of the present invention is to provide a method of adhering multiple polyurethane foam layers together which is applied to stick the multiple polyurethane foam layers successively by way of polyurethane system components in polymerization foaming reaction so as to protect environment.
Secondary objective of the present invention is to provide a method of adhering multiple polyurethane foam layers together which is applied to stick the multiple polyurethane foam layers successively by way of polyurethane system components in polymerization foaming reaction so as to enhance adhesion capacity.
Third objective of the present invention is to provide a method of adhering multiple polyurethane foam layers together which is applied to stick the multiple polyurethane foam layers successively by way of polyurethane system components in polymerization foaming reaction so as to accelerate production.
Fourth objective of the present invention is to provide a method of adhering multiple polyurethane foam layers together which is applied to stick the multiple polyurethane foam layers successively by way of polyurethane system components in polymerization foaming reaction, wherein the polyurethane system components have different properties and start foaming polymerization on and adhere with the multiple polyurethane foam layers, thus enhancing production capacity.
Another objective of the present invention is to provide a method of adhering multiple polyurethane foam layers together which is applied to stick the multiple polyurethane foam layers successively by way of polyurethane system components in polymerization foaming reaction so as to increase sizes of the multiple polyurethane foam layers.
With reference to
It is to be note that the second polyurethane foam layer 17 does not polymerize completely after being delivered away from the press roller 16, for example, the second polyurethane foam layer 17 polymerizes at 80% and does not adhere with the press roller 16. To finish polymerization of the second polyurethane foam layer 17 quickly, a baker 18 is arranged behind the press roller 16 so as to heat and dry the second polyurethane foam layer 17. Alternatively, a heating apparatus is fixed on the press roller 16 so as to heat and dry the second polyurethane foam layer 17. Thereafter, the first polyurethane foam layer 11 and the polyurethane foam layer 17 are adhered and are rolled together by using a second rolling set 10b.
Referring to
It is to be note that the first polyurethane foam layer 27 does not polymerize completely after being delivered away from the first press roller 26, for example, the first polyurethane foam layer 27 polymerizes at 80% and does not adhere with the first press roller 26. To finish polymerization of the first polyurethane foam layer 27 quickly, a first baker 28 is arranged behind the first press roller 26 so as to heat and dry the first polyurethane foam layer 27. Alternatively, a heating apparatus is fixed on the first press roller 26 so as to heat and dry the first polyurethane foam layer 27. Thereafter, the first polyurethane foam layer 27 is conveyed to a second cladding position 29, and second polyurethane system components 30 are evenly cladded on the first polyurethane foam 27 at the second cladding position 29, wherein the second polyurethane system components 30 are identical to or different from the first polyurethane foam layer 23 according to using requirements. When the second polyurethane system components 30 are evenly cladded on the first polyurethane foam layer 27, they start foaming polymerization on the first polyurethane foam layer 27. In this embodiment, the second polyurethane system components 30 are cladded on the first polyurethane foam layer 27 at the second cladding position 29 in a pouring manner or in a spraying manner, wherein a second scraper 32 is mounted behind and mates with a second mixing nozzle 31 so that the second polyurethane system components 30 are cladded evenly, and a cladding thickness of the second polyurethane system components 30 is adjusted by changing a height position of the second scrapper 32 and is determined based on a desired thickness of the second polyurethane foam layer. After starting foaming polymerization on the first polyurethane foam layer 27, the second polyurethane system components 30 enter into gaps of the first polyurethane foam layer 27 so as to adhere with the first polyurethane foam layer 27 securely. Thereafter, the second polyurethane system components 30 and the first polyurethane foam layer 27 are conveyed to a second press roller 33 so that the second polyurethane system components 30 foam to produce the second polyurethane foam layer 34. Preferably, a height position of the second press roller 33 is adjustable so as to control a foaming thickness of the second polyurethane system components 30, and the foaming thickness of the second polyurethane system components 30 is determined based on the desired thickness of the second polyurethane foam layer 34. To avoid the second press roller 33 adhering with the second polyurethane system components 30, Teflon is coated on the second press roller 33 or the second press roller 33 is made of polyethylene (PE) material or a metal foil. Thereafter, the second polyurethane foam layer 34 and the first polyurethane foam layer 27 are delivered away from the second press roller 33, thus foaming and adhering the second polyurethane foam layer 34 with the first polyurethane foam layer 27.
It is to be note that the second polyurethane foam layer 34 does not polymerize completely after being delivered away from the second press roller 33, for example, the second polyurethane foam layer 34 polymerizes at 80% and does not adhere with the second press roller 33. To finish polymerization of the second polyurethane foam layer 34 quickly, a second baker 35 is arranged behind the second press roller 33 so as to heat and dry the second polyurethane foam layer 34. Alternatively, a heating apparatus is fixed on the second press roller 33 so as to heat and dry the second polyurethane foam layer 34. Thereafter, the first polyurethane foam layer 27 and the second polyurethane foam layer 34 are rolled together by using a second rolling set 20b and are removed from the release later 21 by way of a third rolling set 20c.
As shown in
It is to be note that the third polyurethane foam layer 41 does not polymerize completely after being delivered away from the third press roller 40, for example, the third polyurethane foam layer 41 polymerizes at 80% and does not adhere with the third press roller 40. To finish polymerization of the third polyurethane foam layer 41 quickly, a third baker 42 is arranged behind the third press roller 40 so as to heat and dry the third polyurethane foam layer 41. Alternatively, a heating apparatus is fixed on the third press roller 40 so as to heat and dry the third polyurethane foam layer 41. Thereafter, the first polyurethane foam layer 27, the second polyurethane foam layer 34, and the third polyurethane foam layer 41 are adhered and are rolled together by using a second rolling set 20b and are removed from the release layer 21 by way of a third rolling set 20c.
Thereby, the multiple polyurethane foam layers are adhered successively by using polyurethane system components in polymerization foaming reaction so as to protect environment and to enhance adhesion and production capacity. The multiple polyurethane foam layers are capable of being produced in a limited space. Preferably, the method of the present invention is capable of foaming and adhering one polyurethane foam layer with the other polyurethane foam layers so as to enhance production efficiency.
While the preferred embodiments of the invention have been set forth for the purpose of disclosure, modifications of the disclosed embodiments of the invention as well as other embodiments thereof may occur to those skilled in the art. Accordingly, the appended claims are intended to cover all embodiments which do not depart from the spirit and scope of the invention.
