TWI609777B - Elastic pad body manufacturing method - Google Patents

Description

Elastic pad body manufacturing method

The invention relates to the manufacture of a cushion body, in particular to a method for manufacturing an elastic cushion body which can be applied to a site laying.

In the floor structure such as the stadium and the sports field, whether it is indoor or outdoor, although there are different sandwich structures due to different needs, it also contains a basic elastic cushion to provide shock absorption and shock mitigation.

However, the elastic pad body used as the elastic cushion layer in the past is mostly made of a thermoplastic PVC component, so that it is easily deformed when the temperature is raised, and the ability for temperature and abrasion resistance is poor, and the PVC is liable to overflow during use. Toxic substances that are harmful to the human body, and poisons that pollute the environment when processed or incinerated are urgently needed to be improved.

Furthermore, the current automated production techniques for such mats are, as shown in Fig. 1, coated on a substrate that is automatically transported by means of a reciprocating action of the applicator 90 to form a mechanism for automated processing. Usually, the applicator 90 is provided with or connected with a mixing tank 91 for mixing the raw materials supplied from the feeding pipe 92, and then being sprayed by the single-hole discharging head 93, and finally by chemical reaction or subsequent processing. It is solidified and formed; however, when the raw materials are mixed, the curing reaction starts, so the corresponding shaping treatment must be completed in a short time after coating, and thus the applicator The coating range of 90 (related to the width of the finished product) and the conveying speed of the substrate (related to the production efficiency) are greatly limited, and it is difficult to meet the demand for product size or improve the efficiency.

In view of this, the inventors have made many years of manufacturing experience in this industry, and have made improvements in this research, and have continued their efforts to complete the present invention.

The main object of the present invention is to provide a method for manufacturing an elastic pad body, which adopts a long-shaped discharge port for large-area shower coating, effectively improves the limitation of the conventional single-point shower coating, and can provide a large-scale product demand. And increase the production efficiency several times.

In order to achieve the foregoing effects, the main process of the method for manufacturing the elastic pad body of the present invention comprises the steps of mixed shower coating, external heating, internal heating, etc., wherein the mixing and coating step is to use a mixed stirring applicator to polymerize the polymer and the setting agent. Mixing and mixing into a gluing mixture, and reciprocatingly coating the surface of the continuously transported base material with a long strip discharge port; the external heating step is externally heated by baking to heat the outer surface of the gluing mixture The internal heating step is internally heated by infrared osmosis to heat the interior of the glue mixture.

According to the practical requirements, a step of thickness control may be provided between the mixing and the external heating step, which allows the glued glue to be adjusted by the roller to maintain a fixed thickness on the base material; A flattening step may also be provided between the heating step and the internal heating step, which allows the incompletely shaped gluing mixture to be leveled through the platen.

Further, the present invention further provides a method for manufacturing an elastic pad body, which is formed by a two-stage process in which a foam layer and an elastic layer are formed on both sides of the base material, and the main process includes mixing of the foam layer. Steps such as shower coating, external heating, internal heating, and elastic layer Mixing, external heating, internal heating and other steps. Wherein, the process of the foam layer comprises: mixed shower coating, which uses a mixing and stirring applicator to stir and mix the foaming raw material and the styling agent into a first glue mixture, and reciprocates with a long strip discharge port. Applied to one side surface of the continuously conveyed base material; externally heated by external heating by baking to heat set the outer surface of the unshaped first glue mixture to form an incompletely shaped foam layer; Internal heating, which is internally heated by infrared osmosis, heats the interior of the foamed layer to form a fully shaped foamed layer. The process of the elastic layer comprises: mixed shower coating, which uses an additional mixing and stirring applicator to stir the elastic raw material and the styling agent into a second glue mixture in proportion, and reciprocally sprays the strip at the long discharge port. The other side surface of the continuous conveying base material; external heating, which is externally heated by baking, so that the outer surface of the unshaped second glue mixture is heat set to form an elastic layer which is not completely shaped; internal heating, It is internally heated by infrared ray infiltration to heat the interior of the elastic layer to form a completely shaped foam layer.

Similarly, a step of thickness control may be provided between the mixed coating step of the foamed layer and the elastic layer and the external heating step, which allows the unshaped first glued mixture/second glued mixture to be adjusted by the roller. And can maintain a fixed thickness on the base material; another step between the external heating step of the foam layer and the elastic layer and the internal heating step can also be provided with a flattening step, which is to make the foam layer that is not completely shaped/ The elastic layer is leveled by the pressure plate.

Preferably, the control thickness is disposed behind the mixing and stirring applicator with a lateral roller. By controlling the height of the roller, the first glue mixture/second glue mixture passing under the roller can be The base material is maintained at a constant thickness.

Preferably, the pressure plate for leveling comprises an upper pressing plate and a lower pressing plate, which can adjust the spacing between the two through the cylinder, so that the foaming layer/elastic layer which is not completely shaped can be pressed. level.

Preferably, the pressure plates are provided with a conveyor belt on the outer surface of the Teflon to avoid sticking problems; and the mixing and applicator is also provided with an anti-adhesive inner surface of the Teflon.

Preferably, the foaming raw material and the elastic raw material are high molecular polymers.

Preferably, the base material is a non-woven fabric.

In order to achieve a more specific understanding of the above objects, functions and features of the present invention, the preferred embodiments of the present invention and the accompanying drawings are as follows:

10‧‧‧Basic material discharge device

11‧‧‧Transport roller

20‧‧‧ storage trough

30‧‧‧Mixed Stirrer

31‧‧‧Mixed mixing tank

32‧‧‧Inlet pipe

33‧‧‧Drawing head

34‧‧‧Outlet

40‧‧‧ thickness control device

41‧‧‧Roller

42‧‧‧ cylinder

50‧‧‧ baking device

60‧‧‧ leveling device

61‧‧‧Upper plate

62‧‧‧ Lower platen

63‧‧‧ cylinder

64‧‧‧Conveying tape

70‧‧‧Infrared heating device

L1‧‧‧ base material

L2‧‧‧Foam layer

L3‧‧‧ elastic layer

S01~S05‧‧‧Steps

90‧‧‧applicator

91‧‧‧ Mixing trough

92‧‧‧Inlet pipe

93‧‧‧Drawing head

Figure 1 is a schematic diagram of a process of coating.

Fig. 2 is a schematic view showing the appearance of a mixing and applicator according to a preferred embodiment of the present invention.

Figure 3 is a schematic view showing the discharge head and the discharge opening of the mixing and applicator according to a preferred embodiment of the present invention.

Figure 4 is a schematic view of a shower coating process in accordance with a preferred embodiment of the present invention.

Figure 5 is a schematic illustration of a manufacturing apparatus in accordance with a preferred embodiment of the present invention.

Figure 6 is a schematic illustration of a process of a preferred embodiment of the present invention.

Figure 7 is a schematic cross-sectional view showing the pad body of the first stage process according to a preferred embodiment of the present invention.

Figure 8 is a cross-sectional view showing the structure of the second stage process of the preferred embodiment of the present invention.

Referring to Figures 2 to 6, it can be seen that the method for manufacturing the elastic pad body of the present invention comprises a mixed coating step S01, a thickness control step S02, an external heating step S03, and a leveling step S04. And the internal heating step S05 and other processes.

In the present embodiment, the above steps are repeated for the foaming raw material and the elastic raw material, respectively, to form a two-stage processing, and a foamed layer and an elastic layer are respectively formed on both side surfaces of the base material L1. In the arrangement of the equipment, as shown in FIG. 5, the basic equipment of each stage includes a hopper 20, a mixing and stirring applicator 30, a thickness control device 40, a baking device 50, a leveling device 60, and infrared heating. The device 70 can be practiced in various ways, for example, after completing the first stage of processing, replacing the raw materials and then performing the second stage processing; or setting the second stage processing equipment behind the first stage processing equipment, The connecting path is used to invert the pad body; or the first and second stages of the device are arranged in a double layer up and down configuration, and after the first stage processing is completed, the device is turned up or down, and the pad body can be turned over at the same time. The second stage of processing is smoothly carried out.

In the first stage of processing, the foam layer L2 is formed on one side surface of the base material L1 through the above steps S01 to S05 (as shown in FIG. 7). First, the base material L1 is first discharged from the base material. 10 is conveyed to the coating position where the mixing and stirring applicator 30 is located by the conveying roller 11, that is, the mixing and coating step S01 is started; as shown in the second to fourth figures, the mixing and stirring applicator 30 mainly includes the mixing and stirring tank 31. The feeding pipe 32, the discharging head 33 and the discharging port 34 are respectively connected to the storage tank 20 storing the foaming raw material and the setting agent for proportionally drawing the foaming raw material and the setting agent to In the mixing and agitating tank 31, the mixing and mixing tank 31 is stirred and uniformly mixed into a first cementing mixture, so that the curing reaction can be smoothly carried out subsequently; the lower end of the mixing and agitating tank 31 is connected to the discharging head 33, and the discharging head 33 is opened and long. The strip-shaped discharge port 34 allows the first glue mixture after stirring and mixing to smoothly flow out from the discharge port 34 and is sprayed on one side surface of the base material L1 (as shown in FIG. 4). The strip-shaped discharge port 34 can be used to cooperate with the mixing and stirring applicator 30 to reciprocate laterally. Forming a large-area coating, curtain coating by mixing a first uncured glue can be self By diffusion, by adjusting the flow rate of the glue mixture, the moving speed of the applicator, and the conveying speed of the base material L1, the first glue mixture of the spray coating can be effectively controlled to be uniformly distributed on the base material L1.

After the mixed coating step S01, a thickness control step S02 is performed, at which time the coated first glue mixture and the base material L1 are conveyed to the thickness control device 40; wherein the thickness control device 40 includes a lateral roller 41 and a The cylinder 42 can control the relative height of the roller 41 by the cylinder 42, and when the unshaped first glue mixture and the base material L1 pass, the first glue mixture can be adjusted by the roller 41 and uniformly distributed on the base material L1. Maintain a constant thickness.

After the thickness control step S02, an external heating step S03 is performed, at which time the first glue mixture and the base material L1 that complete the thickness adjustment are transported to the baking device 50; in this step, the base material L1 is made by external heating. The outer surface of the first unbonded first glue mixture is shaped by heat to form a chemical reaction, and the inner portion is not completely heated, so that the foam layer L2 which is not completely shaped is formed.

After the external heating step S03, the leveling step S04 is performed, and the externally heated foam layer L2 and the base material L1 are conveyed to the leveling device 60. The leveling device 60 includes an upper pressing plate 61 and a lower pressing plate 62. A cylinder 63 can adjust the position of the upper pressing plate 61 by the cylinder 63 to control the distance between the upper pressing plate 61 and the lower pressing plate 62, so that the base material L1 and the foaming layer L2 pass between the upper and lower pressing plates 61 and 62. The incompletely-formed foam layer L2 can be leveled by pressure; and the upper platen 61 and the lower platen 62 are respectively provided with a take-up reel 64, and the surface of the take-up reel 64 has a Teflon material to reduce sticking. It is also easy to remove the sticky material and make the process of conveying and leveling smoother.

After the leveling step S04, the internal heating step S05 is performed, and the leveling is completed at this time. The foam layer L2 and the base material L1 are transported to the infrared heating device 70; in this step, the inside of the foam layer L2 is not heated by baking to complete the chemical reaction by the infrared penetrating heating method. The portion is thermally molded by irradiation of infrared rays to completely complete the process of curing and setting, and at this time, the first stage of processing is completed, and a completely cured foam layer L2 is formed on one side surface of the base material L1.

As for the processing of the second stage, the above steps S01 to S05 are repeated with different materials, and an elastic layer L3 is formed on the other side surface of the base material L1 (as shown in FIG. 8). In this embodiment, The second stage of processing is performed by another set of equipment having the same storage tank 20, mixing and stirring applicator 30, thickness control device 40, baking device 50, leveling device 60, and infrared heating device 70, Steps S01 to S05 are repeated with a predetermined ratio of the elastic material and the setting agent as raw materials. The operation mode and the structural function of each device are the same as those of the previous first stage, and the description thereof will not be repeated here.

When the second stage of the mixed coating step S01 is performed, the turned-off semi-finished product (the base material L1 and the foamed layer L2) is conveyed to a predetermined coating position, and the mixing and stirring applicator 30 stores the elastic raw material and The sizing agent hopper 20 is proportionally drawn and stirred and mixed into a second glue mixture, and is sprayed on the other side surface of the base material L1 by reciprocating action by a strip-shaped discharge port 34. By adjusting the flow rate of the glue mixture, the moving speed of the applicator, and the conveying speed of the base material L1, the second glue mixture can be uniformly distributed in a state of uniform diffusion distribution after being sprayed. Subsequently, a thickness control step S02 is performed to adjust the thickness of the second glue mixture on the base material L1 by means of the laterally disposed rollers 41. Then, the external heating step S03 is performed, and the outer surface of the unshaped second glue mixture is heat-set by the external heating of the baking device 50 to form an elastic layer which is not completely shaped. Then, the leveling step S04 is performed again, by adjusting The distance between the upper pressing plate 61 and the lower pressing plate 62 is such that the elastic pad body (the base material L1, the foam layer L2 and the incompletely shaped elastic layer L3) passes through the middle of the upper and lower pressing plates 61 and 62, and the elasticity is not completely fixed. Layer L3 can be leveled by the pressure. Finally, the internal heating step S05 is performed, and the infrared heating device 70 performs the penetrating infrared heating to allow the inside of the elastic layer L3 to not completely cure the reaction portion, and can be shaped by heat to form a completely shaped foam layer. After this step is completed, That is, the second stage of processing is completed, and subsequent processes such as receiving or cutting can be performed according to requirements.

It is to be noted that the foaming raw material and the elastic raw material used in the foamed layer and the elastic layer of the present invention are mainly thermosetting polymer PU (polyurethane), which is not only inferior to the thermoplastic PCV component. Poisoning problem, and not subject to thermal deformation and better anti-wear ability, and through the combination of the foam layer L2 and the elastic layer L3 on both sides of the base material L1, can produce better shock absorption and compression properties; The method of thickness control by the roller can improve the problem that the surface of the material is damaged by the scraping method in the past; further, by the manufacturing method of the invention, the coating mechanism of the long strip outlet can greatly improve the production efficiency and thereby reduce Cost, and can break through the specifications of the previous process.

However, the embodiments described above are merely illustrative of the preferred embodiments of the present invention, and are not intended to limit the scope of the patent protection of the present invention, and should be based on the technical idea defined in the scope of the subsequent claims. Variations, modifications, alterations, or equivalent substitutions of the scope of the invention and the scope of the invention are also intended to fall within the scope of the invention.

30‧‧‧Mixed Stirrer

31‧‧‧Mixed mixing tank

32‧‧‧Inlet pipe

33‧‧‧Drawing head

L1‧‧‧ base material

Claims (10)

The invention relates to a method for manufacturing an elastic pad body, which comprises at least the following steps: (A) mixing and mixing a foaming raw material and a styling agent into a first glue mixture by a mixing and stirring applicator, and reciprocating with a long strip discharge port. Spraying on one side surface of the continuously transported base material; (B) externally heating by baking to heat set the outer surface of the unshaped first glue mixture to form an incompletely shaped foam layer; The inside of the foamed layer is heat-set by infrared osmosis to form a completely shaped foamed layer; (D) the elastic raw material and the styling agent are stirred and mixed into a second ratio by a further mixing and stirring applicator. Gluing the mixture and reciprocatingly coating the other side surface of the continuously conveyed base material with a long strip discharge port; (E) external heating by baking to make the unshaped second glue mix The surface is heat-set to form an elastic layer that is not completely shaped; (F) is internally heated by infrared osmosis to heat the interior of the elastic layer to form a fully shaped foam layer. The method for manufacturing an elastic pad according to claim 1, wherein before the step (B) / the step (E), the unshaped first glue mixture/second glue mixture is first adjusted by the roller to the base layer. Maintain a constant thickness on the material. The method for manufacturing an elastic pad according to claim 2, wherein the rollers are controlled at a relative height so that the passed first glue mixture/second glue mixture can be fixed on the base material. thickness of. The method of manufacturing an elastic pad according to claim 1, wherein before the step (C) / step (F), the foam layer/elastic layer which is not completely shaped is first flattened by a press plate. The method of manufacturing an elastic pad according to claim 4, wherein each of the pressure plates is provided with a transporting tape of the outer surface of the Teflon. The method for producing an elastic mat according to claim 1, wherein the foaming raw material and a main component of the elastic raw material are a high molecular polymer PU (polyurethane). The method of manufacturing an elastic pad according to claim 1, wherein the base material is a non-woven fabric. The invention relates to a method for manufacturing an elastic cushion body, which comprises at least the following steps: (A) mixing and mixing a high molecular polymer and a styling agent into a glue mixture by a mixing and stirring applicator, and reciprocating the strip with a long discharge port. Applying to the surface of the continuously conveyed base material; (B) externally heating by baking to heat the outer surface of the glue mixture; (C) internal heating by infrared osmosis to heat the internal heat of the glue mixture . The method of manufacturing an elastic pad according to claim 8, wherein prior to the step (B), the sprayed glued mixture is first adjusted by a roller to maintain a fixed thickness on the base material. The method of manufacturing an elastic mat according to claim 9, wherein before the step (C), the incompletely set gluing mixture is first leveled by a press plate.