Patent Application
20180079184
The present invention relates to a method of adhering a polyurethane foam layer which is applied to successively stick the polyurethane foam layer with at least one surface layer by way of polyurethane system components in polymerization foaming action 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, etc.
As shown in
A method of adhering the polyurethane foam layer 1 with the surface layer 2 contains steps of: cladding adhesive 3 on the polyurethane foam layer 1; and adhering the surface layer 2 on the polyurethane foam layer 1 by way of the adhesive 3. However, the adhesive 3 has defects as follows:
1. The adhesive 3 causes environment damage.
2. The polyurethane foam layer 1 cannot adhere with the surface layer 2 securely by using the adhesive 3.
3. After foaming the polyurethane foam layer 1, the adhesive 3 is cladded on the polyurethane foam layer 1 troublesomely.
4. After foaming the polyurethane foam layer 1, the adhesive 3 is cladded on the polyurethane foam layer 1 so that the polyurethane foam layer 1 adheres with the surface layer 2, but such an adhering method will limit production space.
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 a polyurethane foam layer which is applied to successively stick the polyurethane foam layer with at least one surface layer by way of polyurethane system components in polymerization foaming action so as to protect environment.
Secondary objective of the present invention is to provide a method of adhering a polyurethane foam layer which is applied to successively stick the polyurethane foam layer with at least one surface layer by way of polyurethane system components so as to enhance adhesion capacity.
Further objective of the present invention is to provide a method of adhering a polyurethane foam layer which is applied to successively stick the polyurethane foam layer with at least one surface layer by way of polyurethane system components so as to enhance production capacity.
Another objective of the present invention is to provide a method of adhering a polyurethane foam layer which is applied to successively stick the polyurethane foam layer with at least one surface layer by way of polyurethane system components so as to reduce production space.
With reference to
Referring to
It is to be note that the polyurethane foam layer 17 does not polymerize completely, i.e., the polyurethane foam layer 17 polymerizes at 80% and does not adhere with the press roller 16. Thereafter, the polyurethane foam layer 17 finishes polymerization after 24 hours. To finish polymerization of the polyurethane foam layer 17 quickly, a baker 18 is arranged behind the press roller 16 so as to heat and dry the polyurethane foam layer 17. Alternatively, a heating apparatus is fixed on the press roller 16 so as to heat and dry the polyurethane foam layer 17. Thereafter, the polyurethane foam layer 17 is removed from the release layer 11 by using a third rolling set 10c and a fourth rolling set 10d, and the polyurethane foam layer 17 and the release layer 11 are rolled by the third rolling set 10c and the fourth rolling set 10d, respectively.
As shown in
In this embodiment, the polyurethane system components 22 are cladded on the surface layer 21 in a pouring manner or in a spraying manner, wherein a scraper 24 is mounted behind a mixing nozzle 23 so as to clad the polyurethane system components 22 evenly, and a cladding thickness of the polyurethane system components 22 is adjusted by changing a height position of the scrapper 24 and is determined according to a desired thickness of the polyurethane foam layer. Preferably, the polyurethane system components 22 enter into gaps of the surface layer 21 so as to adhere with the surface layer 21 securely. Thereafter, the surface layer 21 and the polyurethane system components 22 are conveyed to a press roller 25 so that the polyurethane system components 22 foam to produce the polyurethane foam layer 26 which adheres with the surface layer 21. Preferably, a height position of the press roller 25 is adjustable so as to control a foaming thickness of the polyurethane system components 22, and the foaming thickness of the polyurethane system components 22 is determined based on the desired thickness of the polyurethane foam layer 26. To avoid the press roller 25 adhering with the polyurethane system components 22, Teflon is coated on the press roller 25 or the press roller 25 is made of polyethylene (PE) material or a metal foil. Thereafter, the polyurethane foam layer 26 is delivered away from the press roller 25, thus adhering the polyurethane foam layer 26 with the surface layer 21 successively.
It is to be note that the polyurethane foam layer 26 does not polymerize completely, i.e., the polyurethane foam layer 26 polymerizes at 80% and does not adhere with the press roller 25. Thereafter, the polyurethane foam layer 26 finishes polymerization after 24 hours. To finish polymerization of the polyurethane foam layer 26 quickly, a baker 27 is arranged behind the press roller 25 so as to heat and dry the polyurethane foam layer 26. Alternatively, a heating apparatus is fixed on the press roller 25 so as to heat and dry the polyurethane foam layer 26. Thereafter, the polyurethane foam layer 26 is rolled by a rolling set 20b.
As illustrated in
In this embodiment, the polyurethane system components 32 are cladded on the first surface layer 31 in a pouring manner or in a spraying manner, wherein a scraper 34 is mounted behind a mixing nozzle 33 so as to clad the polyurethane system components 32 evenly, and a cladding thickness of the polyurethane system components 32 is adjusted by changing a height position of the scrapper 34 and is determined according to a desired thickness of the polyurethane foam layer. Preferably, the polyurethane system components 32 are delivered to a second surface layer 35 by a second rolling set 30b, after foaming and polymerizing on the first surface layer 31, wherein the second surface layer 35 is identical to or is different from the first surface layer 31 according to using requirements. Preferably, the polyurethane system components 32 enter into gaps of the first surface layer 31 and the second surface layer 35 so as to adhere with the first surface layer 31 and the second surface layer 35 securely. Thereafter, the first surface layer 31, the polyurethane system components 32, and the second surface layer 35 are conveyed to a press roller 36 so that the polyurethane system components 32 foam to produce the polyurethane foam layer 37 which adheres with the first surface layer 31 and the second surface layer 35. Preferably, a height position of the press roller 36 is adjustable so as to control a foaming thickness of the polyurethane system components 32, and the foaming thickness of the polyurethane system components 32 is determined based on the desired thickness of the polyurethane foam layer 37. To avoid the press roller 36 adhering with the polyurethane system components 32, Teflon is coated on the press roller 36 or the press roller 36 is made of polyethylene (PE) material or a metal foil. Thereafter, the polyurethane foam layer 37 is delivered away from the press roller 36, thus adhering the polyurethane foam layer 37 with the first surface layer 31 and the second surface layer 35 successively.
It is to be note that the polyurethane foam layer 37 does not polymerize completely, i.e., the polyurethane foam layer 37 polymerizes at 80% and does not adhere with the press roller 36. Thereafter, the polyurethane foam layer 37 finishes polymerization after 24 hours. To finish polymerization of the polyurethane foam layer 37 quickly, a baker 38 is arranged behind the press roller 36 so as to heat and dry the polyurethane foam layer 37. Alternatively, a heating apparatus is fixed on the press roller 36 so as to heat and dry the polyurethane foam layer 37. Thereafter, the polyurethane foam layer 37 is rolled by a third rolling set 30c.
Accordingly, the polyurethane system components are applied to adhere the polyurethane foam layer with the at least one surface layer successively so as to protect environment and to enhance adhesion and production capacity. In addition, the polyurethane foam layer is capable of being produced in a limited space.
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.
