CN103589047A - 用于汽车脚垫的轻型发泡材料及其制备方法 - Google Patents

用于汽车脚垫的轻型发泡材料及其制备方法 Download PDF

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CN103589047A
CN103589047A CN201310543744.3A CN201310543744A CN103589047A CN 103589047 A CN103589047 A CN 103589047A CN 201310543744 A CN201310543744 A CN 201310543744A CN 103589047 A CN103589047 A CN 103589047A
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文剑军
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Abstract

本发明公开了一种用于汽车脚垫的轻型发泡材料及其制备方法。该发泡材料由原材料经过15-45分钟油压发泡而成，原材料包括质量份数%的乙烯和%的乙烯-醋酸乙烯共聚物颗粒。本发明率先将乙烯和乙烯-醋酸乙烯共聚物颗粒混合原料的发泡材料用于汽车脚垫，使得制备出的汽车脚垫具有轻型、环保的特点；不仅便于拆卸清洗，而且整个材料可以完全回收使用、无污染，环保安全。

Description

用于汽车脚垫的轻型发泡材料及其制备方法
 
技术领域
本发明涉及汽车用品材料领域，特别涉及一种用于汽车脚垫的轻型发泡材料及其制备方法。
 
背景技术
汽车脚垫作为一种比较普遍且实用性很强的汽车用品，必须要有防水、防尘、防滑等功能。目前的汽车脚垫其主要材质包括橡胶、亚麻、棉纤维、超纤仿皮等。这些材料制备的汽车脚垫，为了保障脚垫的防护功能，不仅厚实笨重、不便于清洗，而且生产工艺复杂、成本高，不够环保。
 
发明内容
本发明的目的是针对目前的汽车脚垫材料制备的汽车脚垫厚实笨重、不便拆卸清洗、不够环保的问题，提高了一种新的特别用于汽车脚垫的轻型发泡材料，以及该发泡材料的制备方法。
为了实现上述目的，本发明提供了一种用于汽车脚垫的轻型发泡材料，该发泡材料由原材料经过15-45分钟油压发泡而成，其中所采用的原材料包括质量份数15-25份的低密度聚乙烯和25-35份的乙烯-醋酸乙烯共聚物颗粒。
优选地，原材料还包括质量份数25-35份的碳酸钙填充料、5-15份的色料，以及5-15份的添加剂。
优选地，添加剂包括人造橡胶IR、发泡剂AC-8和交联剂DCP。
优选地，乙烯-醋酸乙烯共聚物颗粒的颗粒规格为3-5目。
本发明的另一面还提高了本发明的轻型发泡材料的制备方法，包括以下步骤：(A)配料，(B)利拿机混炼，(C)滚轮机压片以及(D)油压机发泡。
优选地，利拿机混炼具体包括，先将低密度聚乙烯、乙烯-醋酸乙烯共聚物颗粒、色料和碳酸钙填充料加入利拿机中，加冷却水进行密炼，当材料温度升至90℃-100℃时再加入添加剂继续混炼。
优选地，在利拿机混炼的过程中，分别在材料温度达到98℃-100℃、102℃-104℃、105℃-107℃时进行一次翻料。
优选地，在混炼完成后，倒料的温度控制在105℃-115℃之间。
优选地，滚轮机压片具体包括，采用一个或多个滚轮机将混炼后的材料分阶段压成所需厚度。
更优选地，滚轮机压片具体包括，采用三个滚轮机将混炼后的材料由厚到薄分三次压制成0.8-2mm的片料，以用于后续的发泡；具体的，从第一滚轮机出来的辗压料厚度为8-10mm，然后将其送入第二滚轮机，获得3-4mm的辗压料，最后通过第三滚轮机获得0.8-2mm的片料。
因此，本发明有益效果在于：采用本发明的发泡材料能够制备出轻型、环保的汽车脚垫。在相同尺寸下，本发明的发泡材料制备的汽车脚垫整体质量不到1.5KG，材质轻；并且，由本发明的材料制备的汽车脚垫可以回收，循环使用，没有多余的废弃物或者污染物，不论是生产过程还是循环回收利用过程都不会对环境造成污染，环保安全。
 
具体实施方式
为了使审查员能够进一步了解本发明的目的，现附较佳实施例以详细说明如下，本实施例仅用于说明本发明的技术方案，并非限定本发明。
本例的汽车脚垫以质量份数15-25份的低密度聚乙烯和25-35份的乙烯-醋酸乙烯共聚物颗粒为主要原材料经过15-45分钟油压发泡而成。需要说明的是，本发明率先将低密度聚乙烯和乙烯-醋酸乙烯共聚物颗粒混合原料的发泡材料用于汽车脚垫，使得制备的汽车脚垫具有轻型、环保的特点，不仅便于拆卸、清洗，而且所有脚垫材料都可以回收，循环使用，无污染，环保安全；同时，所制备出的汽车脚垫还能够满足防尘、防水、防滑等功能需求；为汽车脚垫提供了一种革命性的改进。
在改进的实现方式中，为了使得发泡材料能够更好的满足在汽车脚垫中的应用，在上述原材料中还添加有质量份数25-35份的碳酸钙填充料、5-15份的色料，以及5-15份的添加剂；其中，添加剂为人造橡胶IR、发泡剂AC-8和交联剂DCP。并且，优先使用颗粒规格3-5目的乙烯-醋酸乙烯共聚物颗粒。
具体的，本例的汽车脚垫的制备方法包括：
（A）配料：按照本例的轻型发泡材料的配比，根据生产规格，精确称取各组分材料。
（B）利拿机混炼：启动利拿机，先检查各器件是否允许正常；先将低密度聚乙烯、乙烯-醋酸乙烯共聚物颗粒、色料和碳酸钙填充料加入利拿机中，加冷却水进行密炼，当材料温度升至90℃-100℃时再加入添加剂继续混炼；混炼过程中，当材料表面温度升至98℃-100℃时，上升加压盖和防尘盖，翻料，然后加盖继续混炼；当材料表面温度升至102℃-104℃时，上升加压盖和防尘盖，重新翻料，然后加盖继续混炼；当材料表面温度升至105℃-107℃时，上升加压盖和防尘盖，再翻料一次，然后加盖继续混炼；混炼约20分钟后，倒料、清洗机器，进行下一轮作业，倒料温度保持在105℃-115℃之间。混炼后的材料送入滚轮机继续处理。
（C）滚轮机压片：本例分别采用第一滚轮机、第二滚轮机和第三滚轮机进行制片；具体的，先开启滚轮机检查有无机器异常，将滚轮温度控制在60℃-70℃，用四轮表面温度计测量，每小时测量一次。在第一滚轮机处时：将滚压料厚度调解3-4mm，翻料二次；调节辗压料厚度为1-2mm，翻料二次；调节辗压料厚度8-10mm，再翻料二次；将等份的材料分别横放入1/3架内，并将1/3料架移至第二滚轮机旁。在第二滚轮机处：同样的，先开启第二滚轮机空转5分钟，检查机器有无异常，控制滚轮温度60℃-70℃；调解辗压厚度为8-10mm在1/3料架中自上而下，拿3份料辗压一次；调节辗压厚度为1-2mm，翻料二次；调节辗压厚度为3-4mm，翻料二次；边翻料边出料至第三滚轮机。在第三滚轮机处：开启机器空转1分钟，检查机器有无异常，控制滚轮温度65℃-85℃；调节出片厚度0.8-2mm，采用误差0.01mm的游标卡尺测量，调整出片宽度：大片为62mm、小片为55mm；获得所需尺寸的片料。需要说明的是，采用滚轮机的个数与最终需要的片料的厚度有关，可以理解，如果需要更薄的片料，还可以采用更多个数的滚轮机，或者不需要更薄的厚度时，也可以采用少于三个的滚轮机，这些都在本发明的保护范围内。
（D）将步骤（C）制备的片料按照需要的规格进行裁剪，然后置于油压机中进行发泡，约发泡15-45分钟即获得本例的用于汽车脚垫的轻型发泡材料。需要说明的是，发泡时间15-45分钟是本例经过试验得出的结论，是可以制备出满足汽车脚垫需要的有效发泡时间；可以理解，发泡时间与发泡程度是有关的，在较低的工艺要求中，发泡时间可以不受15-45分钟的限定。
需要说明的是，在后续的加工步骤中，为了获得各种尺寸的汽车脚垫，或者为了获得各种效果或不同表面纹理的脚垫，还需要对步骤（D）制备的轻型发泡材料进行裁剪或雕饰。
 
上述发明内容及具体实施方式意在证明本发明所提供技术方案的实际应用，不应解释为对本发明保护范围的限定。本领域技术人员在本发明的精神和原理内，当可作各种修改、等同替换或改进。本发明的保护范围以所附权利要求书为准。

Claims (10)

1.一种用于汽车脚垫的轻型发泡材料，其特征在于：所述发泡材料由原材料经过15-45分钟油压发泡而成，所述原材料包括质量份数15-25份的低密度聚乙烯和25-35份的乙烯-醋酸乙烯共聚物颗粒。
2.根据权利要求1所述的用于汽车脚垫的轻型发泡材料，其特征在于：所述原材料还包括质量份数25-35份的碳酸钙填充料、5-15份的色料，以及5-15份的添加剂。
3.根据权利要求2所述的用于汽车脚垫的轻型发泡材料，其特征在于：所述添加剂包括人造橡胶IR、发泡剂AC-8和交联剂DCP。
4.根据权利要求1-3任一项所述的用于汽车脚垫的轻型发泡材料，其特征在于：所述乙烯-醋酸乙烯共聚物颗粒的颗粒规格为3-5目。
5.根据权利要求1-4任一项所述的轻型发泡材料的制备方法，包括以下步骤：(A)配料，(B)利拿机混炼，(C)滚轮机压片以及(D)油压机发泡。
6.根据权利要求5所述的制备方法，其特征在于：所述利拿机混炼具体包括，先将低密度聚乙烯、乙烯-醋酸乙烯共聚物颗粒、色料和碳酸钙填充料加入利拿机中，加冷却水进行密炼，当材料温度升至90℃-100℃时再加入添加剂继续混炼。
7.根据权利要求6所述的制备方法，其特征在于：在利拿机混炼的过程中，分别在材料温度达到98℃-100℃、102℃-104℃、105℃-107℃时进行一次翻料。
8.根据权利要求6所述的制备方法，其特征在于：在混炼完成后，倒料的温度控制在105℃-115℃之间。
9.根据权利要求5所述的制备方法，其特征在于：所述滚轮机压片具体包括，采用一个或多个滚轮机将混炼后的材料分阶段压成所需厚度。
10.根据权利要求5所述的制备方法，其特征在于：所述滚轮机压片具体包括，采用三个滚轮机将混炼后的材料由厚到薄分三次压制成0.8-2mm的片料，以用于后续的发泡；具体的，从第一滚轮机出来的辗压料厚度为8-10mm，然后将其送入第二滚轮机，获得3-4mm的辗压料，最后通过第三滚轮机获得0.8-2mm的片料。
CN201310543744.3A 2013-11-06 2013-11-06 用于汽车脚垫的轻型发泡材料及其制备方法 Pending CN103589047A (zh)

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CN1276290A (zh) * 1999-06-07 2000-12-13 王子斌 橡塑微孔防滑拖鞋及制备方法
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CN101376351A (zh) * 2008-08-19 2009-03-04 东莞市宏恩塑胶制品有限公司 一种环保立体汽车脚垫及其制备方法
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Publication number Priority date Publication date Assignee Title
CN1276290A (zh) * 1999-06-07 2000-12-13 王子斌 橡塑微孔防滑拖鞋及制备方法
CN1626574A (zh) * 2003-12-08 2005-06-15 厦门市同安德阳鞋业有限公司 一种用于制鞋的香味eva发泡材料及其加工工艺
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