CN106166017A - 一种回收橡胶发泡颗粒制成的仿旧抗疲劳垫及其制备方法 - Google Patents

一种回收橡胶发泡颗粒制成的仿旧抗疲劳垫及其制备方法 Download PDF

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CN106166017A
CN106166017A CN201610570458.XA CN201610570458A CN106166017A CN 106166017 A CN106166017 A CN 106166017A CN 201610570458 A CN201610570458 A CN 201610570458A CN 106166017 A CN106166017 A CN 106166017A
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严红君
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Ningbo Bohan Crafts Co Ltd
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Abstract

本发明公开了一种回收橡胶发泡颗粒制成的仿旧抗疲劳垫，包括从上往下依次设置的涂料图案层、回收橡胶发泡颗粒层以及底层，所述涂料图案层经做旧处理。本发明还提供了一种上述抗疲劳垫的制备方法，先将回收橡胶发泡材料颗粒化，然后与胶水混合均匀，在模具内热压成型，再通过胶水与底层压力复合制得抗疲劳垫的半成品；然后将半成品清洁后，喷涂涂料再打磨制得成品。对涂料图案层进行打磨做旧处理，使其具备不同的时尚风格，满足不同的消费群体，市场前景更好，并且采用回收的橡胶发泡材料，可以大大降低生产成本，而且将回收的橡胶发泡材料颗粒化，充分利用回收橡胶发泡材料的弹性，可以有效缓解长时间处于固定位置引起的身体疲劳。

Description

一种回收橡胶发泡颗粒制成的仿旧抗疲劳垫及其制备方法
技术领域
本发明涉及一种仿旧抗疲劳垫及其制备方法，特别是一种回收橡胶发泡颗粒制成的仿旧抗疲劳垫及其制备方法。
背景技术
目前市场上在使用的能够缓解疲劳的抗疲劳垫，大都采用橡胶、PU、XPE各种发泡材料制成，主要是利用发泡材料的弹性起到缓解疲劳的作用。然而这种抗疲劳垫存在一定的缺点：即该种垫子在色彩与图案上只追求光鲜亮丽，风格单一，与典雅、欧尚的装修风格不协调，消费群体狭隘有局限性，并且生产成本还比较高。
发明内容
为了解决上述现有技术的不足，本发明的目的是提供一种回收橡胶发泡颗粒制成的仿旧抗疲劳垫，不但可以降低生产成本，而且可以在垫子表面做旧，使其具备不同的时尚风格，满足不同的消费群体。
为了实现上述目的，本发明所设计的一种回收橡胶发泡颗粒制成的仿旧抗疲劳垫，包括从上往下依次设置的涂料图案层、回收橡胶发泡颗粒层以及底层，所述涂料图案层经做旧处理。
优选的，所述涂料图案层的涂料为PU涂料、醇酸涂料或环氧树脂涂料中的一种或多种。
优选的，所述底层为PU发泡层或SBR发泡层或NR发泡层或天然纤维面料层或合成纤维面料层。
本发明的另一目的是提供一种回收橡胶发泡颗粒制成的仿旧抗疲劳垫的制备方法，包括以下步骤：
（1）、将回收橡胶发泡材料清洗后分别粉碎成0.5~3mm、3~8mm两种粒径范围的颗粒；
（2）、将粉碎后的颗粒按照粒径大小，分别投入到两个容器内，再加入胶水搅拌均匀；
（3）、将混合有胶水的橡胶发泡颗粒，按照粒径小的在下、粒径大的在上，均匀放入模具内，进行热压得到回收橡胶发泡颗粒层；
（4）、将回收橡胶发泡颗粒层冷却至常温状态；
（5）、对冷却后的回收橡胶发泡颗粒层进行修边，然后在回收橡胶发泡颗粒层底部辊涂胶水，并传送到烘道内烘烤；
（6）、将烘烤后的回收橡胶发泡颗粒层与底层放入模具内，进行压力复合成型，并切边制得抗疲劳垫的半成品；
（7）、在切边后的半成品的上表面喷涂涂料，并在涂料层上制得图案，形成涂料图案层；
（8）、用砂纸对涂料图案层进行打磨，制得上述仿旧抗疲劳垫。
优选的，所述步骤（3）中热压复合时的温度为160~180℃，压力为13~15MPa，时间为100~160s。
优选的，所述步骤（5）中的烘道温度为80~150℃，烘烤时间为15~20min。
优选的，所述步骤（6）中压力复合时的压力为10~15MPa/cm2。
优选的，所述步骤（7）中在喷涂涂料之前对半成品表面进行清洁，然后进行二次涂料喷涂，并且第二次喷涂在第一次喷涂的涂料自然干燥后进行，第二次喷涂的涂料自然干燥后进行制图。
优选的，所述胶水为PU油性胶水。
与现有技术相比，本发明得到的一种回收橡胶发泡颗粒制成的仿旧抗疲劳垫及其制备方法，其有益效果是：
1、位于该垫子最上面的是涂料图案层，并对图案层进行打磨做旧处理，使其具备不同的时尚风格，满足不同的消费群体，市场前景更好，并且涂料层提高了垫子表面的耐磨强度，延长了使用寿命；
2、采用回收的橡胶发泡材料，可以大大降低生产成本，并且将回收的橡胶发泡材料颗粒化，充分利用回收橡胶发泡材料的弹性，可以有效缓解长时间处于固定位置引起的身体疲劳；
3、在回收橡胶发泡颗粒层下方设置底层，底层可以是具有弹性的发泡层也可以是天然纤维、合成纤维面料层，从而可以进一步提高抗疲劳垫的弹性或者在下层设置凹凸防滑图案，使该抗疲劳垫的功能更加多样化，使用范围更广；
4、橡胶发泡颗粒层采用两种不同粒径范围的颗粒热压复合而成，并且粒径小的颗粒在下面，粒径大的颗粒在上面，使抗疲劳垫的弹性更好；
5、通过该制备方法制得的抗疲劳垫的邵氏硬度为20~30HA，达到缓解疲劳的最佳效果。
具体实施方式
下面结合实施例对本发明进一步说明。
实施例1：
本发明提供的一种回收橡胶发泡颗粒制成的仿旧抗疲劳垫，包括从上往下依次设置的涂料图案层、回收橡胶发泡颗粒层以及底层，所述涂料图案层经做旧处理。
所述涂料图案层的涂料为PU涂料、醇酸涂料或环氧树脂涂料中的一种或多种，并可以在涂料上通过丝网印、喷印等工艺印制各种图案，然后经过磨砂等工艺对图案进行做旧处理。其中，涂料中可以加入适量的颜料，使其色彩更加丰富。
所述底层为PU发泡层或SBR发泡层或NR发泡层或天然纤维面料层或合成纤维面料层，甚至是其他各种材质各种工艺制成的地毯。
上述回收橡胶发泡颗粒制成的仿旧抗疲劳垫的制备方法，包括以下步骤：
（1）、将回收橡胶发泡材料清洗后分别粉碎成0.5~3mm、3~8mm两种粒径范围的颗粒；
（2）、将粉碎后的颗粒按照粒径大小，分别投入到两个容器内，再加入胶水搅拌均匀，胶水的投放量达到回收橡胶发泡材料的颗粒充分包裹即可；
（3）、将混合有胶水的橡胶发泡颗粒，按照粒径小的在下、粒径大的在上，均匀放入模具内，进行热压得到回收橡胶发泡颗粒层，其中热压复合时的温度为160~180℃，压力为13~15MPa，时间为100~160s；
（4）、将回收橡胶发泡颗粒层冷却至常温状态；
（5）、对冷却后的回收橡胶发泡颗粒层进行修边，然后在回收橡胶发泡颗粒层底部辊涂胶水，并传送到烘道内烘烤，烘道温度为80~150℃，烘烤时间为15~20min，烘烤的目的是为了使胶水达到最佳粘合状态，最佳粘合状态一般为用手触摸时粘手又不带胶水的状态；
（6）、将烘烤后的回收橡胶发泡颗粒层与底层放入模具内，进行压力复合成型，并切边制得抗疲劳垫的半成品，其中压力复合时的压力为10~15MPa/cm2；
（7）、对切边后的半成品上表面进行清洁，然后对上表面进行二次涂料喷涂，第一次涂料喷涂使其掩盖上表面的瑕疵，并在自然干燥后进行第二次涂料喷涂，等到第二次喷涂的涂料自然干燥后，再通过丝网印、喷印等工艺进行制图，从而形成涂料图案层；
（8）、根据设计风格的需要，用200目的水磨砂纸沾肥皂液对涂料图案层进行有规律的打磨实现做旧处理，制得上述仿旧抗疲劳垫。
先将回收的橡胶发泡材料进行颗粒化，并将颗粒按照粒径0.5~3mm、3~8mm进行划分，粒径过小或者过大均会影响最终成型垫子的弹性和复合牢度，然后将颗粒化的橡胶发泡材料与胶水混合均匀，否则也会影响成型效果和最终成型垫子的局部回弹效果，将粒径小的橡胶发泡材料位于下方、粒径大的橡胶发泡材料位于上方进行热压复合，采用这种方式制得橡胶发泡颗粒层不但弹性好，而且硬度适中，踩上去达到不失去支撑又能起到缓解疲劳的效果，然后在橡胶发泡颗粒层与底层复合修边后，再清洁橡胶发泡颗粒层喷涂涂料印制图案制得涂料图案层，并对涂料图案层进行打磨做旧处理，使其风格多样化，满足不同的消费群体。
对比例1：
该对比例中与实施例1区别仅仅在于：该回收橡胶发泡颗粒的粒径在0.3mm，其余同实施例1 。
对比例2：
该对比例与对比例1的区别仅仅在于回收橡胶发泡颗粒的粒径在12mm。
对比例3：
该对比例与实施例1的区别在于：回收橡胶发泡颗粒层的上层颗粒粒径为0.3mm，下层颗粒粒径为12mm，其余同实施例1。
对比例4：
该对比例与实施例1的区别在于：回收橡胶发泡颗粒层的上层颗粒粒径为12mm，下层颗粒粒径为0.3mm，其余同实施例1。
对比例5：
该对比例与实施例1的区别仅仅在于：胶水为PU水性胶水。
对对比例1~5制取的抗疲劳垫进行检测，得出邵氏硬度均在5~10HA，抗疲劳效果较差。
综上所述，通过本发明的制备方法制得的抗疲劳垫的抗疲劳效果最佳；且该抗疲劳垫的风格更加多样化，可以满足不同的消费群体。
以上所述实施例仅仅是对本发明的实施方式进行描述，并不能因此而理解为对本发明专利范围的限制。应当指出的是，对于本领域的普通技术人员来说，在不脱离本发明构思的前提下，还可以做出若干变形和改进，这些均属于本发明的保护范围。因此，本发明专利的保护范围应以所附权利要求为准。

Claims (9)

1.一种回收橡胶发泡颗粒制成的仿旧抗疲劳垫，其特征在于：包括从上往下依次设置的涂料图案层、回收橡胶发泡颗粒层以及底层，所述涂料图案层经做旧处理。
2.根据权利要求1所述的回收橡胶发泡颗粒制成的仿旧抗疲劳垫，其特征在于：所述涂料图案层的涂料为PU涂料、醇酸涂料或环氧树脂涂料中的一种或多种。
3.根据权利要求1所述的回收橡胶发泡颗粒制成的仿旧抗疲劳垫，其特征在于：所述底层为PU发泡层或SBR发泡层或NR发泡层或天然纤维面料层或合成纤维面料层。
4.根据权利要求1-3任一所述的回收橡胶发泡颗粒制成的仿旧抗疲劳垫的制备方法，其特征在于包括以下步骤：
（1）、将回收橡胶发泡材料清洗后分别粉碎成0.5~3mm、3~8mm两种粒径范围的颗粒；
（2）、将粉碎后的颗粒按照粒径大小，分别投入到两个容器内，再加入胶水搅拌均匀；
（3）、将混合有胶水的橡胶发泡颗粒，按照粒径小的在下、粒径大的在上，均匀放入模具内，进行热压得到回收橡胶发泡颗粒层；
（4）、将回收橡胶发泡颗粒层冷却至常温状态；
（5）、对冷却后的回收橡胶发泡颗粒层进行修边，然后在回收橡胶发泡颗粒层底部辊涂胶水，并传送到烘道内烘烤；
（6）、将烘烤后的回收橡胶发泡颗粒层与底层放入模具内，进行压力复合成型，并切边制得抗疲劳垫的半成品；
（7）、在切边后的半成品的上表面喷涂涂料，并在涂料层上制得图案，形成涂料图案层；
（8）、用砂纸对涂料图案层进行打磨，制得上述仿旧抗疲劳垫。
5.根据权利要求4所述的仿旧抗疲劳垫的制备方法，其特征在于：所述步骤（3）中热压复合时的温度为160~180℃，压力为13~15MPa，时间为100~160s。
6.根据权利要求4所述的仿旧抗疲劳垫的制备方法，其特征在于：所述步骤（5）中的烘道温度为80~150℃，烘烤时间为15~20min。
7.根据权利要求4所述的仿旧抗疲劳垫的制备方法，其特征在于：所述步骤（6）中压力复合时的压力为10~15MPa/cm2。
8.根据权利要求4所述的仿旧抗疲劳垫的制备方法，其特征在于：所述步骤（7）中在喷涂涂料之前对半成品表面进行清洁，然后进行二次涂料喷涂，并且第二次喷涂在第一次喷涂的涂料自然干燥后进行，第二次喷涂的涂料自然干燥后进行制图。
9.根据权利要求4所述的仿旧抗疲劳垫的制备方法，其特征在于：所述胶水为PU油性胶水。
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