CN100551690C - 弹性地板衬垫及其制作方法 - Google Patents
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Abstract
一种弹性衬垫,其用于地板(1),如用于运动活动的地板的人工草皮(1),其包括:第一层压结构(21、22)以及第二层结构(24、25),两层包绕其之间的囊(22a),所述的囊包含颗粒弹性材料(23)。结构(21、22;24、25)由无纺织物层(21、25)粘结到聚烯烃层(22、24)上形成。聚烯烃层(22、24)包围其之间的所述囊(22a)。所述的囊(22a)为具有正方形基层,侧边为20-60mm,一般为45mm,高度在20-40mm之间,一般为30mm。颗粒弹性材料(23)按5-20kg/m2充填在所述的囊(22a)内。所述的颗粒弹性材料(23)为回收轮胎粉碎颗粒,其大小在0.5-7.0mm之间。
Description
技术领域
本发明涉及一种弹性地板衬垫。
本发明衬垫特别关注与运动设施地板的结合使用,但其实际上可以为所有运动活动,而且也可以为摔伤或进行外科手术的人员康复提供一种可控弹性的地板衬底。同时也有助于小孩在操场活动时的安全性。
背景技术
特别地,本发明适合与专利EP-A-1158099公开的人工草皮结合使用。人工草皮包括:一基础层,该基础层具有从其底部延伸出的多个纤维状结构,这些纤维状结构模仿自然生长的草地;以及分散于纤维状结构之间的颗粒充填物质,以使这些纤维状结构保持大体垂直。颗粒充填物质由一些大体匀质的颗粒材料形成,这些颗粒材料由聚烯烃基材料及乙烯基聚合体基材制成。
这种方案的进一步改进在EP-A-1319753、EP-A-1375750、EP-A-1371779以及EP-A-1486613中都有描述,所有这些文档归属于本专利申请的申请人。
人们关注人工草皮这一具体领域之外,很少关注地板铺设的常规条件,无论是为动运活动设计的地板还是其它类型的地板。除了设计足够平坦的铺设表面并在户外铺设地板的情况下,为了具有良好的排水性(因为地面凹凸不面造成排水困难)之外,一般认为地板通常应该铺在地面基础上,例如铺在水泥做的跑道上,或铺在夯实的地面上。这样的话就存在一个问题,如果地基不均衡,和/或不能够预料,一些用于运动设施的地板只能临时铺在预先存在的地板甚至路基上。对于工业、商业以及居民铺设地板也存在类似问题。
特别地,本发明涉及一种地板衬垫具有如US-A-3813279公开的特征。
本发明的目的就是提供一种能够克服上述缺点的方案,能够完全满意地或预先高度确定的条件下铺设任何一种地板(例如,用于运动设施的地板,如人工草皮)。
发明内容
根据本发明,上述目的通过具有权利要求中所述特征的衬垫来实现。
权利要求形成了本发明的一个完整部分。
本发明适合于生产和使用一种弹性衬垫(技术术语“震动垫”),用于为运动设施结构提供一种理想性能,特别是为人工草皮的结构提供理想的性能。
相应的产品垫子有不同的形状,厚度,结构及设计。每个不同的产品都针对于具体的需求和/或理疗和康复需求。
对于足求场来说,此处公开的方案可用于替代水泥和沥青做的场地。对于篮球和排球的室内操场,以及多用途室内操场,为了消除水泥场地的刚性,可以让运动地板具有吸收震动性能以及足够弹性屈服性,这些性能对于延长训练以及各水平的竞赛是必需的,能够消除运动员在不适合的地板表面训练时造成的损伤风险(在运动场,对于各种运动场地都有明确的标准)。
本发明公开的方案也可以用在健身及康复运动中,优选适合于术后康复活动,这是由于可以缓冲肢体接触地板时的冲击,而不会造成如接触刚性表面造成能量反弹的结果。
本发明公开的方案可以满足安全的需要,如公园、公共机构如学校以及幼儿园中小孩的运动区域,能够缓冲跳落地面冲击,使用这些结构防止了身体损伤。
本发明公开的方案同样适合于在工作区域的使用,在工作区域,工人必需长时间站立(如付款台、收银台、售票室),使用该方案,工人将不会经受由于刚性表面造成的疲劳。
总之,根据本发明获得的不同的产品对应于不同的需求,如运动特性以及安全和康复特性。
附图说明
本发明将通过非限定性实施例并结合附图进一步进行叙述。
图1为用于运动设施的地板结构的总体剖视图,如人工草皮以及本发明的衬垫;
图2为本发明衬垫局部切割的透视图;
图3为所述衬垫局部的平面图;
图4到图8说明制造前述衬垫的连续步骤。
具体实施方式
在图1中,标记1指地板整体,此处通过用于运动活动的地板举例说明,该地板由人工草皮结构构成,人工草皮包括两部分:基础层部分2;以及多个纤维结构3,其从基础层2延伸,模仿自然生长的植被。
无论是哪种情况,应当强调本发明的用途不局限于例举的地板类型。实际上,根据本发明的方案可以用于任何一种类型的地板,能够完全满意地或预先高度确定的条件下铺设任何一种地板。
人工草皮1的结构如图1所示,在纤维结构3之间充填一种颗粒充填材料(也称作“填实材料”)4,以保持纤维结构大体垂直。所述充填材料最好由基本均质的颗粒材料形成,这些颗粒材料由聚烯烃基材料及乙烯基聚合体基材制成。
然而,本发明的技术方案与是否利用人工草皮或充填材料没有关系。
在普通的人工草皮1的铺设条件下,基础层2设计在弹性衬垫20上,弹性衬垫的性能将在下面做充分的说明。
在图1,可以看到纤维结构3有未梢、顶端,具有柔软绒长的外观,即自立的基桩形状。但本发明公开的方案应用到这样的人工草皮上,这种人工草皮的纤维结构3具有卷曲的结构,其赋予结构1的外观整体感觉是毛绒型或织物型的,一般称作“毛卷型”。
基本上,铺设的衬垫20具有通常称作“震动垫”,使用于各种运动活动的结构,特别是对于人工草皮具有理想的生物机械特性。
在此处说明的实例中,衬垫20(图1中有意在其它部分中突出以使其特征更加清楚)具有总体分层的结构,分层结构中各部分可以相同。
参照图1中显示的铺设条件,下面将从顶到底顺序描述所述分层结构,这种结构优选于户外铺设。另一方面,一定要考虑在某些使用条件下(例如室内或/和比较薄且使用率高的地板),衬垫20的铺设条件可以相对于图1中的位置翻转180度来铺设。
从上到下的第一层为一层无纺织物(NW)21,普遍为称作“连续单丝无纺土工织物”的材料,经过针毡型处理得到。例如,所说的材料具有200-400g/m2的重量(根据标准UNI EN ISO 965,单位面积质量),通常为300g/m2,优选由聚酯制成。
层21结合到60-120g/m2,一般为90g/m2的聚烯烃层22上(如低密度聚烯烃-LDPE)。这种复合层经过热压得到平行六面体形的囊。这种平行六面体为具有20-60mm,一般为45mm边的四方形基础上,其高度为20-40mm,一般为30mm。
这种预热压囊以5-20kg/m2充填例如颗粒弹性物质23。这种弹性物质如回收轮胎粉碎颗粒。粒颗弹性物质23优选粒颗大小为0.5-0.7mm。充填量的多少依囊的大小而不同,当前填充量在5-20kg/m2的范围内,一般为12kg/m2。
紧接着下面为复合层24、25,大体上与上述的层21和22的设置相同。因此,聚烯烃层24(如低密度聚烯烃-LDPE)的重量为60-120g/m2,一般为90g/m2,其热压粘接到一般称作“连续单丝无纺土工织物”的材料形成的层上。例如,层25的材料具有200-400g/m2的重量(根据标准UNI EN ISO 965,单位面积质量),通常为300g/m2,优选由聚酯制成。
两层聚烯烃层22、24相互热封,盖在含有颗粒物质23的囊上,以使封闭所述颗物质,以形成各个独立的囊,其容纳物不渗透。
由于囊基本不渗透水和湿汽,这样就防止囊中的物质或组成向外接触和/或转移/释放,甚至在低温上保证了良好的压缩性能。结果是可以使用一些不同原料如轮胎和/或衬圈经磨粹的回收材料。所述的材料经上述的封囊后不会释放到任何含有如芳香胺和/或已知的PAH(由标准ISO13877定义)的物质环境中,从而不会有任何不利的生态影响。
上述的衬垫20这种结构的组合更清楚地从图2的透视图中看到,其中只显示了衬垫20,而没有显示其上面的地板。
再者,即使衬垫20在铺设的条件下图示时,含有颗粒物质23的囊,实际上就是相对于层24和25的平面向上的突起在铺设条件下相对于层24和25的平面变成向下突出了。
上述的衬垫20产品的系列可以从层21(如土工织物材料,一般有市售)开始,利用业内熟知的方法将其热压粘接(图1)到层22上,业内熟知的方法此处不再做描述了。
通过复合材料构成的第一层压结构经热压得到上述的囊,也就是图5所指的22a。
在形成的结构倒过来后(即如图5所示的没有进行热压时形成的囊22a,这时其向上开口),囊22a充填上颗粒材料23(如图6所示)。
第二层压结构,由复合层24、25构成(如图7),根据与形成复合层21、22基本相同的形式形成,利用已知的热封工具T热封在已在装配流水线上的第一层结构上,进行封囊,提供每个独立的囊,从而其容纳物不会渗透。
最后得到的是地板1的弹性衬垫,其包括第一层压结构21、22,和第二层压结构24、25,第一和第二层压结构包围形成囊22a,在囊中含有充填物颗粒弹性材料23。
按照需求进行应用是很明显的,最后的处理操作就是提供排水孔26,其直径3-4mm,例如可以位于囊的侧缘和/或角落,从图3可以很清楚地看到。其它的应用(如室内环境)也是很明显的,例如层21、22、24、25的封闭将提供一个连续性的结构,其具有阻隔水蒸汽的功能。
由此获得的层压结构可以平板/板材形或者薄板/圈绕形。平板/板材的尺寸范围为120×105cm,囊的表面面积为1.26m2,囊的四方形基础具有大于30mm的侧边,其高度大于30mm。在薄板/圈绕形中,囊的四方形基础的侧边尺寸小于30mm,高度小于30mm。
在实际应用中,上述衬垫材料可直接应用到所谓的动态或静态排水底衬上,这样免去了铺设沥青基础的需要。动态技术方案大体上为经压缩及卷绕的层,其通过利用具有中/大尺寸的高排驱性及抗载性的含钙物质,在其充填层表面上形成4/5cm的火山物质和砂土,分散并卷绕,直到获得的基础层可以适合于人工覆盖物的铺设。
在上述得到的基础层上铺设其它物质,可以在地板铺设前,在衬垫20的表面分散一层砂土,例如厚度为5-10mm。在图1中,所述的砂子辅助层用S来表示,砂子S主要分部在相邻囊之间的槽中。
在衬垫20上砂土的分布(或其它颗粒物质)根据整个衬垫20和其上的地板/覆盖层的生物机械性能不同而选择。
上述的最终得到的衬垫遵从FIFA标准(手册,2005年2月28日出版),能量吸收(必需大于60%),垂直变形不大于8mm。每个囊的形状和尺寸的不同,从而其吸收/返回的能量不同将视特殊运动活动的功能而定。
本发明的衬垫具有十分优秀的抗压性能,抗形变性能,能量吸收性能,原料的质量控制,冷热条件下的良好表现,良好排水性,较低安装费用、持续时间长,长期性能的保证,优秀的大小稳定性,自然运动特性以及较低的环境影响。
当然,本发明的原理的没有预见的详细结构及实施例相对于所述的及图示的非限定性实例将会有所不同,但并不能脱离本发明权利要求限定的范围,其应用也不局限于本发明特别描述的用于运动活动的地板如人工草皮。
Claims (34)
1、一种用于地板(1)的弹性衬垫,其包括:第一层压结构(21、22)以及第二层结构(24、25),两层封装其之间的囊(22a),所述的囊包含颗粒弹性材料(23),
其特征在于:至少所述的第一层压结构(21、22)和所述第二层压结构(24、25)之一由无纺织物层粘结到聚烯烃层上形成,所述第一层压结构(21、22)和第二层压结构(24、25)封装其之间的所述囊(22a)。
2、根据权利要求1所述的弹性衬垫,其特征在于:所述的无纺织物层为连续单丝无纺土工织物。
3、根据权利要求1所述的弹性衬垫,其特征在于:所述的无纺织物层的重量为200-400g/m2。
4、根据权利要求3所述的弹性衬垫,其特征在于:所述的无纺织物层的重量为300g/m2。
5、根据权利要求1所述的弹性衬垫,其特征在于:所述的无纺织物层为聚酯基。
6、根据权利要求1所述的弹性衬垫,其特征在于:所述的聚烯烃层(22)的重量为60-120g/m2。
7、根据权利要求6所述的弹性衬垫,其特征在于:所述的聚烯烃层(22)的重量为90g/m2。
8、根据权利要求1所述的弹性衬垫,其特征在于:所述的聚烯烃层(22)为聚乙烯基。
9、根据权利要求8所述的弹性衬垫,其特征在于:所述的聚烯烃层(22)为低密度聚乙烯(LDPE)。
10、根据权利要求1所述的弹性衬垫,其特征在于:所述的囊(22a)为平行六面体形状。
11、根据权利要求10所述的弹性衬垫,其特征在于:所述的囊(22a)为具有正方形基层。
12、根据权利要求11所述的弹性衬垫,其特征在于:所述的囊(22a)的侧边为20-60mm。
13、根据权利要求12所述的弹性衬垫,其特征在于:所述的囊(22a)的侧边为45mm。
14、根据权利要求10或11所述的弹性衬垫,其特征在于:所述的囊(22a)的高度在20-40mm之间。
15、根据权利要求14所述的弹性衬垫,其特征在于:所述的囊(22a)的高度为30mm。
16、根据权利要求1所述的弹性衬垫,其特征在于:颗粒弹性材料(23)按5-20kg/m2充填在所述的囊(22a)内。
17、根据权利要求16所述的弹性衬垫,其特征在于:颗粒弹性材料(23)按12kg/m2充填在所述的囊(22a)内。
18、根据权利要求16或17所述的弹性衬垫,其特征在于:所述的颗粒弹性材料(23)为回收轮胎粉碎颗粒。
19、根据权利要求18所述的弹性衬垫,其特征在于:所述的颗粒弹性材料(23)的大小在0.5-7.0mm之间。
20、根据权利要求1所述的弹性衬垫,其特征在于:所述第一层压结构(21、22)和所述第二层压结构(24、25)将含有所述颗粒材料(23)的囊封闭,形成各个单独的囊,其容纳物不渗透。
21、根据权利要求1或20所述的弹性衬垫,其特征在于:含有所述颗粒材料(23)的囊由所述第一层压结构(21、22)和所述第二层压结构(24、25)中的两层聚烯烃层封闭形成,该两层聚烯烃层密封在一起。
22、根据权利要求1所述的弹性衬垫,其特征在于:其包括有设置在所述囊(22a)的侧缘和/或角落的排水孔。
23、根据权利要求1所述的弹性衬垫为平板。
24、根据权利要求1所述的弹性衬垫为板材形。
25、根据权利要求23或24所述的弹性衬垫,其特征在于:所述平板或板材形的衬垫大小范围为120×105cm。
26、根据权利要求23或24所述的弹性衬垫,其特征在于:所述囊的四方形基础的边长大于30mm,高度大于30mm。
27、根据权利要求1所述的弹性衬垫为薄板或卷绕形。
28、根据权利要求27所述的弹性衬垫,其特征在于:所述囊的四方形基础的边长小于30mm,高度小于30mm。
29、根据权利要求1所述的弹性衬垫,其与铺在其上面的地板(1)相结合。
30、根据权利要求29所述的弹性衬垫,其特征在于:所述地板是用于运动设施的地板(1)。
31、根据权利要求29所述的弹性衬垫,其特征在于:所述用于运动设施的地板为人工草皮(1)。
32、制备根据权利要求1-13,15-17,19-20,22-24,27-31任一项所述的弹性衬垫的方法,其特征在于:包括如下步骤:
提供所述的第一层压结构(21、22);
利用所述第一层压结构(21、22)得到所述的囊(22a),
将所述颗粒材料(23)充填在所述囊(22a)中;
提供所述的第二层压结构(24、25);
将所述第二层压结构(24、25)应用到所述充填有所述颗粒材料(23)的囊(22a)上以封闭所述的囊(22a)。
33、根据权利要求32所述的方法,其特征在于:通过热压,从所述第一层压结构(21、22)得到所述的囊(22a)。
34、根据权利要求32所述的方法,其特征在于:还包括将所述第二层压结构(24、25)热封压在充填有所述颗粒材料(23)的所述囊(22a)上。
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US20040163345A1 (en) * | 2002-01-04 | 2004-08-26 | Alderman Robert J. | Blanket heat insulation with facing radiant barrier |
EP1375750B1 (en) | 2002-06-17 | 2009-07-22 | Mondo S.p.A. | A process for producing synthetic-grass structures and corresponding synthetic-grass structure |
NL1021171C2 (nl) * | 2002-07-29 | 2004-01-30 | Hugo De Vries | Werkwijze voor het aanleggen van een begaanbaar oppervlak, bijvoorbeeld een speelveld en zo gevormd oppervlak. |
JP2004232365A (ja) * | 2003-01-31 | 2004-08-19 | Toray Ind Inc | アンダーパッド |
EP1604813B1 (en) * | 2003-03-19 | 2011-06-08 | Asahi Kasei Fibers Corporation | Nonwoven polyester fabric with high resistance to water pressure |
ATE359401T1 (de) | 2003-06-10 | 2007-05-15 | Mondo Spa | Verwendung eines bestimmten einstreumaterial in einem kunstrasen, entsprechender kunstrasen |
US7083147B2 (en) * | 2004-03-11 | 2006-08-01 | The Boeing Company | Modularized insulation, systems, apparatus, and methods |
US20060130363A1 (en) * | 2004-12-17 | 2006-06-22 | Michael Hottinger | Shoe sole with a loose fill comfort support system |
-
2005
- 2005-05-27 AT AT05425378T patent/ATE402289T1/de active
- 2005-05-27 ES ES05425378T patent/ES2311951T3/es active Active
- 2005-05-27 DK DK05425378T patent/DK1726715T3/da active
- 2005-05-27 PT PT05425378T patent/PT1726715E/pt unknown
- 2005-05-27 DE DE602005008399T patent/DE602005008399D1/de active Active
- 2005-05-27 PL PL05425378T patent/PL1726715T3/pl unknown
- 2005-05-27 EP EP05425378A patent/EP1726715B1/en active Active
-
2006
- 2006-05-15 CA CA002546884A patent/CA2546884A1/en not_active Abandoned
- 2006-05-23 JP JP2006142988A patent/JP4758283B2/ja not_active Expired - Fee Related
- 2006-05-23 CN CNB2006100811577A patent/CN100551690C/zh active Active
- 2006-05-23 US US11/439,005 patent/US8221856B2/en not_active Expired - Fee Related
Patent Citations (1)
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US3813279A (en) * | 1970-12-16 | 1974-05-28 | Gen Tire & Rubber Co | Elastic foam carpet underlay |
Also Published As
Publication number | Publication date |
---|---|
DE602005008399D1 (de) | 2008-09-04 |
US20060269703A1 (en) | 2006-11-30 |
EP1726715A1 (en) | 2006-11-29 |
PT1726715E (pt) | 2008-09-24 |
PL1726715T3 (pl) | 2009-01-30 |
CN1869376A (zh) | 2006-11-29 |
JP4758283B2 (ja) | 2011-08-24 |
CA2546884A1 (en) | 2006-11-27 |
JP2006328944A (ja) | 2006-12-07 |
US8221856B2 (en) | 2012-07-17 |
ES2311951T3 (es) | 2009-02-16 |
EP1726715B1 (en) | 2008-07-23 |
DK1726715T3 (da) | 2008-11-17 |
ATE402289T1 (de) | 2008-08-15 |
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