CN1229025A - 聚合物泡沫基材及其作为装饰表面的用途 - Google Patents

聚合物泡沫基材及其作为装饰表面的用途 Download PDF

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CN1229025A
CN1229025A CN98122646A CN98122646A CN1229025A CN 1229025 A CN1229025 A CN 1229025A CN 98122646 A CN98122646 A CN 98122646A CN 98122646 A CN98122646 A CN 98122646A CN 1229025 A CN1229025 A CN 1229025A
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M·因格拉姆
M·克雷赤
R·马福蒂
T·奥里瑟
J·贡扎勒斯
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Abstract

本发明提供一种在装饰组合物中用作基材的聚合物泡沫组合物,在基材上该装饰组合物具有至少一层装饰层,其中该基材是采用一种或多种发泡剂、通过发泡一种由(i)一种或多种聚合物的树脂基体和(ii)填料构成的组合物制备的,所述的一种或多种聚合物选自丙烯腈－丁二烯－苯乙烯(ABS)聚合物、聚碳酸酯、聚苯乙烯、聚苯醚和聚氯乙烯聚合物(优选得自回收塑料)。在诸如层压地板、固体表面层压板、柜台面等各种以层压板为主的装饰产品的制备中,所得的泡沫组合物具有足以替代纤维板或碎料板用途的物理和机械性能。

Description

聚合物泡沫基材及其作为装饰表面的用途
本发明涉及具有合适的机械性能的一种泡沫聚合物组合物，在诸如层压地板、桌面、柜台面和壁板这样的应用中，该组合物用作装饰表面的基材。
常规的层压制品在本领域中是公知的。一般采用诸如蜜胺甲醛和酚醛树脂这样不同类型的树脂、通过相互叠压装饰层和一层或多层牛皮纸层来制造它们。然后将制成的装饰层压板粘合在一种通常由纤维板或碎料板制成的基材上。将这样制造的产品称为高压装饰层压板。另一方面，采用与高压装饰层压板中所用类型相同的树脂、通过直接将一种具有或不具有覆盖层的装饰层叠压到纤维板或碎料板基材上来制造低压装饰层压板。然而，当这类以木材为主基材的应用提供了用于诸如地板和柜台面这样的结构用途的必要的刚性时，在湿气存在的情况下这些以木材为主的基材过重并且易弯曲。
对于这些问题来说，一种可行的解决方案是采用聚合物的基材来制造层压板。然而，聚合物材料往往是相当昂贵的，特别是适于在层压板应用中使用的具有理想的刚性和性能特征的那些物质。
泡沫聚合物是公知的并且将它们用于各种结构的最终用途。Kirk Othmer的《化学技术百科全书》(第4版，11卷，John Wiley和Sons，纽约，pp.730-783(1997))以及由D.Klempner和K.C.Frisch编辑的《聚合物泡沫和发泡技术手册》(Hanser出版社，纽约(1991)中描述了聚合物泡沫的制备和它们的常规用途，将上述两文献的内容引入本文作为参考。
另一个存在的问题是聚合物废物的产生，如产生的残渣或者通过废弃应用聚合物材料的各种商业产品诸如产品的外壳、支座和内部零件而产生的物质。这类产品包括诸如电视机、立体声装置、计算机、打印机、打字机等这样的物品。由于这些产品的特性和围绕它们的技术的迅速进步，这些类型的产品正以渐增的频率被取代。由此引发的一个问题是如何以一种对环境安全的方式、以及以一种经济有效的方式处理这些设备的以聚合物为主的元件。
因此，有用的是得到一种克服上述以木材为主的基材缺陷的基材材料、而同时花费最小的成本。此外，如果这样一种基材是由聚合物材料制成的，那么这有助于得至一种由回收的聚合物中制成的产品。
因此，本发明的一个目的是提供一种具有足够刚性和机械性能的聚合物泡沫组合物，该组合物适于在结构和装饰用途、诸如层压地板或装饰层压板中用作基材。
本发明进一步的目的是提供一种具有上述性能、由回收的塑料制成的聚合物泡沫组合物。
通过多层装饰组合物的发现已经实现了本发明的这些和其它的目的，该组合物包括：
一种包括聚合物泡沫的基材，其中该聚合物泡沫通过发泡一种组合物来制备，该组合物包括(ⅰ)一种选自丙烯腈-丁二烯-苯乙烯(ABS)聚合物、聚碳酸酯、聚苯乙烯、聚苯醚与聚氯乙烯聚合物的一种或多种聚合物的树脂基材和(ⅱ)一种填料，采用的发泡剂选自放热发泡剂、吸热发泡剂及其混合物；和
一层或多层粘合于所述基材的至少一侧表面的装饰层；并且在各种应用中这种多层装饰组合物的使用传统上受限于以碎料板或纤维板为主基材的装饰层压板，例如层压地板和高压装饰层压柜台面、桌面等。
当连同附图考虑时，由于通过参考下列详细地描述同样的内容变得更好理解，所以很容易获得对本发明更全面的评价和许多其附带优点，其中：
附图1表示一种典型的层压结构，该结构显示了基材(1)、装饰层压层(2)和背衬层(3)。
本发明涉及一种具有足以在诸如层压地板、高压装饰层压柜台面等层压型产品中用作心板的结构特性的聚合物泡沫基材以及具有该聚合物泡沫组合物作为心板的层压型产品。
本发明的聚合物泡沫基材可由任何能够发泡的聚合物制备，条件是所制备的泡沫具有为预计的最终用途所必须的结构和机械性能。特别地，具有一种与常规介质或高密度纤维板或碎料板近似相同或者比其更好的压缩变定的基材是优选的(其中当厚度下降作为抗压应力的函数时，压缩变定依照ASTM F970来测定)。在2000磅/英寸2下，优选这种厚度下降至多是0.01英寸，更优选至多是0.005英寸，且最优选至多是0.001英寸。此外，本发明的聚合物泡沫基材优选具有7×10-5-0.1×10-5英寸/英寸/°F的线性热膨胀系数(依照ASTM D-696)，更优选2×10-5-0.5×10-5英寸/英寸/°F，最优选1×10-5-0.6×10-5英寸/ⅰ英寸/°F。
优选的情况是，该聚合物泡沫包括选自诸如阻燃ABS树脂和玻璃填充ABS树脂这样的聚(丙烯腈/丁二烯/苯乙烯)(下文称作ABS)树脂、聚碳酸酯、耐冲击聚苯乙烯(HIPS)、聚苯乙烯、聚苯醚(PPO)和聚氯乙烯(PVC)的一种或多种聚合物。该聚合物可以是未曾使用的或回收的聚合物。优选的情况是，该基材泡沫是用一种共混合的树脂体系制成的，该体系包括、但不限于上面列出的一种或多种聚合物。此外，可以填充或不填充这些聚合物，不过，从一种耐冲击强度和物理特性的观点看，填充过的聚合物是最好的。在一个最优选的实施方案中，由来自诸如计算机、打印机、电视机、立体声装置等电器设备的再生塑料壳和零件来制备这种聚合物。该再生塑料是通过以下方式获得：从电器设备中基本上清除一切以铁类为主的金属和其它非塑料零件，随后将塑料造粒。在本发明的上下文内，术语“基本上”指的是电器设备中以铁类为主的金属和其它非塑料零件原始含量大于95％，优选原始含量大于99％。再生塑料一般是上述优选聚合物的两种或多种的混合物，该混合物具有50％或更多、优选75％或更多的ABS且含有或不含阻燃剂或玻璃填料。
可采用诸如放热发泡剂、吸热发泡剂或二者联用这样的任何常规的发泡剂使用于制备本发明聚合物泡沫的聚合物发泡，条件是可以调节泡沫的孔度以提供预定的最终用途中所需的结构和机械特性。在本领域中泡沫聚合物的制备方法是公知的并且进行过描述，例如，在上述Kirk Othmer的《化学技术百科全书》和《聚合物泡沫和发泡技术手册》中所述。
优选的放热发泡剂包括偶氮二碳酰胺发泡剂。在制备泡沫中放热发泡剂易于提供一种比吸热发泡剂更大的孔度。优选的吸热发泡剂是碳酸钙(或碳酸氢钙)和一种羧酸混合物。泡沫制备领域中适合的羧酸是公知的并且它们能够有助于引发由碳酸钙或碳酸氢钙形成CO2。这类羧酸包括、但不限于酸类、诸如柠檬酸。在高承载的最终用途、诸如层压地板中，由于过大的孔度，所以仅使用一种放热发泡剂往往形成一种具有不足以对抗压缩的阻力的泡沫，而单独使用吸热发泡剂需要较大量的发泡剂(于是提高了材料和加工成本)，不具备产生足够的密度减小的能力以将泡沫总重量减小至适于操作性能的所需水平。因此，在本发明一个优选的实施方案中，发泡剂是一种放热发泡剂和一种吸热发泡剂的混合物。特别地，最优选的发泡剂是偶氮二碳酰胺发泡剂和CaCO3(或碳酸氢钙)/羧酸的混合物。所需发泡剂的量和吸热/放热发泡剂的比例由聚合物泡沫制备领域内的普通技术人员测定并且取决于所需的最终泡沫特性。优选的情况是，按聚合物重量计，所用发泡剂的量可达到聚合物的3％，更优选1-2％。
为了获得产生的泡沫的所需物理特性，可以将本发明的聚合物单独使用或与一种或多种填料联用。优选的情况是，该填料可以是一种或多种常规填料，更优选选自碳酸钙、滑石、硅石、玻璃纤维、氧化铝和硅灰石的一种或多种填料。这些填料还包括经表面处理的填料。最优选的情况是，填料是经表面处理的碳酸钙、作为来自Dalton,GA的Franklin Industrial Minerals的DF30T市售可得。树脂：填料的比例范围是100∶0-30∶70，优选90∶10-50∶50，更优选75∶25-65∶35。
在一个说明性的实施方案中，将再生聚合物与经表面处理的碳酸钙(DF30T)填料按70∶30的树脂：CaCO3的比例进行配料。配成的单独一个类型的颗粒就是发泡剂。可以将这种单一类型的颗粒由占再生聚合物大多数的同一树脂制备、或用存在于再生聚合物混合物中的一种不同的树脂制备。然后，将含颗粒的发泡剂按足以引起发泡剂至约1.5％含量(以总的混合物为基准)的量加入再生聚合物/填料混合物中。直接挤出和吹塑产生的混合物。另一方面，在挤压机中将发泡剂本身(以未颗粒化的形式)直接加入再生聚合物/填料混合物。使聚合物发泡至一种密度减小的水平以满足预定最终用途的需要。至于非承重用途，可使该聚合物起泡至直到75-80％的密度减小水平。对于非承重用途、诸如柜台面和地板用途来说，优选使该聚合物发泡至达到约50％的密度减小水平，更优选25-35％密度减小水平，并且最优选30％的密度减小水平。本发明中使用的密度减小水平是泡沫产品密度低于非泡沫聚合物密度的百分率。
可将本发明的泡沫聚合物产品用作适合各种广泛最终用途的基材。特别地，在层压产品、诸如耐磨层压地板和和高压装饰层压板(例如用于厨房的柜台面和桌面)中，可将本发明的泡沫产品用作纤维板或碎料板基材的替代品。其它的用途包括作为用于固体表面单层板(通常称作1/8″的固体表面加工材料，一般是包含各种填料的聚丙烯酸，诸如Wilsonart International,Inc.销售的SSV产品)和固体表面层压产品(＜100密耳厚度的固体表面加工产品)的基材，也替代了纤维板。在这种应用中，将发泡的聚合物组合物单独挤出、然后与固体表面单层板或层压板进行粘合，或者，就固体表面层压板(如美国申请08/899,118所公开的内容，将其引入本文作为参考)而言，将本发明的聚合物泡沫组合物与固体表面层压板一起共挤压以形成一种多层共挤压的产品。其它的用途包括作为用于各种装饰层、高压或者低压层压板、以及非层压装饰涂布层的基材。这些不同产品中所用层压层的制造在本领域中是公知的。
借助于实例描述本发明泡沫组合物作为一种用于层压地板的基材的用途。然而，由于本领域熟炼技术人员不难认识到本发明的泡沫组合物在许多不同的最终用途内中广泛范围的适用性，所以不应将这看作将本发明限制在层压地板的应用上。
附图1表示了一种典型的层压产品结构，该结构显示了基材(1)、装饰层压层(2)和背衬层(3)。
在制造一种层压产品的过程中，通常采用在上面已印好预定图案的装饰纸层来制造装饰表面。就地板而言，尽管任何图案都可以，但是图案常常是木纹加工的。将这种装饰层浸渍蜜胺甲醛树脂并且叠压在一张或多张牛皮纸上，已经将该牛皮纸浸渍了酚醛树脂。在成品中露出的装饰层表面通常通过粘合一覆盖层来制造，特征在于将薄纸页用同样类型的蜜胺甲醛树脂进行了浸渍。优选的情况是，对于地板应用来说，为了在成品上提供抗磨性和防滑表面，在覆盖层中也包括填料。适合的填料包括氧化铝、碳酸钙、磨碎的玻璃纤维、毛玻璃纤维等。
一旦制成了装饰层，就可以采用常规的粘合剂将其粘合在本发明聚合物泡沫芯部组合物上，这些粘合剂是：诸如聚乙酸乙烯酯/聚氨酯粘合剂、聚氯丁二烯压合式粘合剂、1组份聚氨酯粘合剂、2组份聚氨酯粘合剂、和其它以溶剂为主的粘合体系。从粘合剂和成本两个观点一起考虑，最优选的是聚乙酸乙烯酯/聚氨酯粘合剂。
含有本发明的聚合物泡沫组合物的地板剖面底部是一种用于高压装饰层压板和常用层压地板中的常规后板。该后板是通过叠压一页或多页浸渍有蜜胺甲醛树脂的牛皮纸制造的。也采用如上所述的常规粘合剂将所得的层压板粘合在聚合物泡沫组合物的下侧。
显然，根据上面讲授的内容可以对本发明进行另外的修改和变动。因此，可以理解的是在所附的权利要求的范围内除本文所特别说明以外可以实施本发明。

Claims (10)

1．一种多层装饰组合物，包括：
一种包含聚合物泡沫的基材，其中采用一种发泡剂、通过发泡一种组合物来制备该聚合物泡沫，所述的组合物包括(ⅰ)选自丙烯腈-丁二烯-苯乙烯(ABS)聚合物、聚碳酸酯、聚苯乙烯、聚苯醚与聚氯乙烯聚合物组的一种或多种聚合物的一种树脂基体和(ⅱ)一种填料，采用的发泡剂选自放热发泡剂、吸热发泡剂及其混合物；和
一层或多层粘合于所述基材的至少一侧表面的装饰层。
2．权利要求1的多层装饰组合物，其中所述的树脂基体包括至少一种选自阻燃剂ABS聚合物和玻璃填充ABS聚合物的聚合物。
3．权利要求1的多层装饰组合物，其中所述的树脂基体包括至少一种选自高冲击聚苯乙烯(HIPS)的聚合物。
4．权利要求1的多层装饰组合物，其中所述的树脂基体是使用一种方法、通过回收电器设备而得到的，所述的方法包括：从电器设备中基本上清除一切非塑料零件并且将剩余的塑料造粒。
5．权利要求1的多层装饰组合物，其中所述的装饰层包括一种浸渍了蜜胺甲醛树脂的装饰纸。
6．权利要求5的多层装饰组合物，进一步包括一种在所述装饰纸上的浸渍了所述树脂的覆盖层。
7．权利要求5的多层装饰组合物，在位于所述的装饰纸和所述的基材之间进一步包含一层或多层浸渍了酚醛树脂的牛皮纸。
8．权利要求1的多层装饰组合物，其中所述的基材在所述基材相对两侧的每一侧面上具有一层装饰层。
9．权利要求1的多层装饰组合物，其中所述的装饰层是通过将所述的装饰层与所述的基材进行共挤压而制造的。
10．权利要求9的多层装饰组合物，其中所述的装饰层是一种固体表面加工的单层板或一种固体表面加工的层压板。
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CN100371374C (zh) * 2001-10-18 2008-02-27 波利玛利欧洲股份公司 可发性乙烯基芳族聚合物及其制备方法
CN102575476A (zh) * 2009-09-24 2012-07-11 皇家飞利浦电子股份有限公司 包括照明系统的地板覆盖物系统
CN112543835A (zh) * 2018-05-23 2021-03-23 I4F许可有限责任公司 多用途砖片系统、砖片覆盖物和砖片
CN112203850A (zh) * 2018-05-28 2021-01-08 凸版印刷株式会社 树脂浸渍装饰板用装饰纸、树脂浸渍装饰纸及树脂浸渍装饰板

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AU722520B2 (en) 2000-08-03
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CO5040094A1 (es) 2001-05-29
KR19990045539A (ko) 1999-06-25
EP0919367A2 (en) 1999-06-02
AU8937298A (en) 1999-06-17
ZA9810688B (en) 2000-05-23
BR9805005A (pt) 1999-11-23
IL126699A0 (en) 1999-08-17
ID22094A (id) 1999-09-02
JPH11227083A (ja) 1999-08-24
SG83691A1 (en) 2001-10-16
US6139945A (en) 2000-10-31
NZ332367A (en) 2000-02-28
AR017665A1 (es) 2001-09-12

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