CN106240109A - 一种采用真空贴合的弹性复合体加工工艺 - Google Patents

一种采用真空贴合的弹性复合体加工工艺 Download PDF

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CN106240109A
CN106240109A CN201610641361.3A CN201610641361A CN106240109A CN 106240109 A CN106240109 A CN 106240109A CN 201610641361 A CN201610641361 A CN 201610641361A CN 106240109 A CN106240109 A CN 106240109A
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CN106240109B (zh
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杨明治
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Dongguan Kaibo Biotechnology Co., Ltd
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Dongguan Boorkaee Shoes Material Co
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Abstract

本发明涉及一种复合材料的加工工艺，尤指一种采用真空贴合的弹性复合体加工工艺，主要包括步骤：1）弹性复合体结构设定、2）选取模具、3）发泡成型、4）叠置贴合、5）真空紧密贴合、6）密封储存，本发明的弹性复合体可利用在多个领域中，起到弹性保护作用，本发明通过将基材与废料结合共同发泡成型为具备具体形状的弹性复合体，通过选定模具可成型为所需形状，在成型过程中，既可重复利用残余废料，亦可在无需裁剪修改的情况下减少废料余料的产生，有利于环保工业长期发展；同时本发明通过合理地选材与合理的操作工艺以完成多层复合结构的结合塑型，并且塑型效果好，整体紧密结实，又能达到耐磨防滑、柔软舒适、减震有弹性的效果。

Description

一种采用真空贴合的弹性复合体加工工艺
技术领域
本发明涉及一种复合材料的加工工艺，尤指一种采用真空贴合的弹性复合体加工工艺。
背景技术
在长期以来积累的经验中可获知，弹性物质为生活、学习、工作及工业作业领域均带来不少的益处，因为弹性物质既可以起到缓冲保护作用，又可以增强接触舒适度，还可以因其柔软韧性而使得该物质耐用实用。有史以来，弹性物质从天然纤维发展到工业加工的高分子材料，就目前的发展趋势而言，高分子复合材料的生产技术日益成熟，其运用越来越广泛，优势也越来越多，而且人们的生活工作对其的需要量也日益剧增，然而，正因为其生产量大，导致工业加工后出现的橡胶、泡棉、树脂原料等的废料、边角料、余料量亦随之剧增，这些残余料在不处理的情况下虽然不会污染环境，但是长期如此明显会导致资源浪费、而且占据的空间资源也非常大，若对其进行焚烧处理，燃烧排放的废气必定会造成环境污染，若进行填埋处理，因其不可降解而对大地环境造成危害，因此，残余料的处理是一个亟待解决的问题。
另一方面，弹性物质为增强耐磨擦性能、使用舒适度以及防护作用，单层的材料结构已不能满足要求，因此需要多层复合结构以提升其质量以及满足需求，虽然现已存在有不少多层复合结构，传统的贴合方法需采用加热的方式以贴合，但是加热方式仅适用于平面材料的贴合，用于有特殊形状的弹性物质也加工不完善，尤其是现常见的多层材料在贴合时紧密度不够，导致贴合不稳定，容易产生气泡与表面不匀的问题，这些弹性物质运用在生活中时，也容易产生开胶脱胶问题，而且对人体皮肤接触时的舒适度太低。
发明内容
为解决上述问题，本发明旨在公开一种复合材料的加工工艺，尤指一种采用真空贴合的弹性复合体加工工艺。
为实现上述目的，本发明采用的技术方案是：一种采用真空贴合的弹性复合体加工工艺，其特征在于，所述弹性复合体加工工艺主要包括以下步骤：
1）弹性复合体结构设定：所述弹性复合体的结构层包括基底层、发泡体、热熔胶涂布层、弹性层、接触层和防尘外膜；
2）选取模具：选取铝合金模具为弹性复合体中发泡体的发泡及成型的模具，发泡模具为不定型的发泡室，发泡模具在其上模、下模分别开设间隔排列的通气小孔，孔直径为0.4-0.7mm，孔间距为25-30mm；成型模具为曲面鞋垫、曲面护具或者弧面护套形状，亦或者立体片材、板材、型材形状，发泡体通过选取的成型模具选择性成型为所需形状；
3）发泡成型：首先在发泡模具中填入搅碎且搅拌均匀的发泡原料，主要包括发泡基材、软泡废料、发泡剂、催化剂和其余发泡辅料，合模后将发泡模具放置在发泡蒸箱内并通入蒸汽进行发泡，所通入的蒸汽压力为0.5-0.8MPa，然后采用60-80℃的温度预热40s，预热完成后升温至116-126℃进行加热，加热时间为9-18min，发泡原料受热软化并且发泡膨胀，逐渐形成熔融状态的熔结体；然后将发泡熔结体挤塑到成型模具中，模具合模后加压定型并且静置成型8-12h，冷却脱模后取出已定型的待用发泡体；
4）叠置贴合：弹性复合体的结构层由下至上依次为基底层、发泡体、弹性层和接触层，两结构层之间涂覆热熔胶涂布层，并以防尘外膜包围覆盖在整体的外表面；进行叠置贴合时，将基底层、发泡体、弹性层和接触层通过热熔胶涂布层依次逐层初步贴合为所述弹性复合体；
5）真空紧密贴合：将步骤4）初步贴合的弹性复合体转移至真空贴合机中进行紧密贴合，真空贴合机采用的贴合模具为可加热的抽真空铝板，通过模具的上模、下模形成封闭的真空贴合区，所述的弹性复合体在完成初步贴合时，结构层之间由于溶胶厚积不均或者贴合不均匀而存在凹凸不均的溶胶层，以及结构层之间由于贴合不紧而产生气泡；将弹性复合体置于抽真空贴合区内，通过抽真空作用将弹性复合体的结构层之间存在的气泡抽除，使得贴合紧密，同时通过抽真空及加热作用：加热方式为先预热后逐渐升温，温度控制范围为32-220℃，以将结构层连接产生的凹凸不均的溶胶层抚平，从而使得弹性复合体表面整齐并能完成塑型；
6）密封储存：将两薄片防尘外膜铺设在步骤5）的弹性复合体的上下表面，防尘外膜的表面积比弹性复合体表面积大，两防尘外膜超出弹性复合体边缘的部分为粘合区，通过热压合粘合区形成防尘防水的密封整体。
所述发泡原料的原料组分主要包括：发泡基材56-66份、软泡废料24-34份、发泡剂0.51-0.71份、催化剂0.36-1.20份和其余发泡辅料0.50-1.50份，其余发泡辅料主要由稳定剂、填充剂、调节剂组成。
所述的发泡基材为可发性EPS原料、PVC树脂原料、聚氨酯树脂原料或EVA树脂原料。
所述的软泡废料为橡胶碎料、聚氨酯边角料、软质PVC废料或EVA余料，或者混合余料。
所述弹性复合体的基底层为耐磨橡胶，弹性层为TPU膜或者PU膜、弹性布料，厚度为1.2-2.1mm；防尘外膜为PVC薄膜或者PET薄膜，厚度为0.11-0.36mm，接触层为PE纤维。
所述的发泡模具、成型模具在填入发泡原料之前可涂覆有机硅脱模剂。
本发明的有益效果体现在：本发明的弹性复合体可利用在多个领域中，起到弹性保护作用，本发明通过将基材与废料结合共同发泡成型为具备具体形状的弹性复合体，通过选定模具可成型为所需形状，在成型过程中，既可重复利用残余废料，亦可在无需裁剪修改的情况下减少废料余料的产生，有利于环保工业长期发展；同时本发明通过合理地选材与合理的操作工艺以完成多层复合结构的结合塑型，并且塑型效果好，整体紧密结实，又能达到耐磨防滑、柔软舒适、减震有弹性的效果，而所采用的防尘外膜具备防尘防潮包装作用，从而节省包装工序。
具体实施方式
下面详细说明本发明的具体实施方式：
一种采用真空贴合的弹性复合体加工工艺，所述弹性复合体加工工艺主要包括以下步骤：
1）弹性复合体结构设定：所述弹性复合体的结构层包括基底层、发泡体、热熔胶涂布层、弹性层、接触层和防尘外膜；
2）选取模具：选取铝合金模具为弹性复合体中发泡体的发泡及成型的模具，发泡模具为不定型的发泡室，发泡模具在其上模、下模分别开设间隔排列的通气小孔，孔直径为0.4-0.7mm，孔间距为25-30mm；成型模具为曲面鞋垫、曲面护具或者弧面护套形状，亦或者立体片材、板材、型材形状，发泡体通过选取的成型模具选择性成型为所需形状；
3）发泡成型：首先在发泡模具中填入搅碎且搅拌均匀的发泡原料，主要包括发泡基材、软泡废料、发泡剂、催化剂和其余发泡辅料，合模后将发泡模具放置在发泡蒸箱内并通入蒸汽进行发泡，所通入的蒸汽压力为0.5-0.8MPa，然后采用60-80℃的温度预热40s，预热完成后升温至116-126℃进行加热，加热时间为9-18min，发泡原料受热软化并且发泡膨胀，逐渐形成熔融状态的熔结体；然后将发泡熔结体挤塑到成型模具中，模具合模后加压定型并且静置成型8-12h，冷却脱模后取出已定型的待用发泡体；
4）叠置贴合：弹性复合体的结构层由下至上依次为基底层、发泡体、弹性层和接触层，两结构层之间涂覆热熔胶涂布层，并以防尘外膜包围覆盖在整体的外表面；进行叠置贴合时，将基底层、发泡体、弹性层和接触层通过热熔胶涂布层依次逐层初步贴合为所述弹性复合体；
5）真空紧密贴合：将步骤4）初步贴合的弹性复合体转移至真空贴合机中进行紧密贴合，真空贴合机采用的贴合模具为可加热的抽真空铝板，通过模具的上模、下模形成封闭的真空贴合区，所述的弹性复合体在完成初步贴合时，结构层之间由于溶胶厚积不均或者贴合不均匀而存在凹凸不均的溶胶层，以及结构层之间由于贴合不紧而产生气泡；将弹性复合体置于抽真空贴合区内，通过抽真空作用将弹性复合体的结构层之间存在的气泡抽除，使得贴合紧密，同时通过抽真空及加热作用：加热方式为先预热后逐渐升温，温度控制范围为32-220℃，以将结构层连接产生的凹凸不均的溶胶层抚平，从而使得弹性复合体表面整齐并能完成塑型；
6）密封储存：将两薄片防尘外膜铺设在步骤5）的弹性复合体的上下表面，防尘外膜的表面积比弹性复合体表面积大，两防尘外膜超出弹性复合体边缘的部分为粘合区，通过热压合粘合区形成防尘防水的密封整体；
所述发泡原料的原料组分主要包括：发泡基材56-66份、软泡废料24-34份、发泡剂0.51-0.71份、催化剂0.36-1.20份和其余发泡辅料0.50-1.50份，其余发泡辅料主要由稳定剂、填充剂、调节剂组成；
所述的发泡基材为可发性EPS（聚苯乙烯）原料、PVC（聚氯乙烯）树脂原料、聚氨酯树脂原料或EVA树脂原料；
所述的软泡废料为橡胶碎料、聚氨酯边角料、软质PVC（聚氯乙烯）废料或EVA余料，或者混合余料；
所述弹性复合体的基底层为耐磨橡胶，弹性层为TPU膜或者PU膜、弹性布料，厚度为1.2-2.1mm；防尘外膜为PVC（聚氯乙烯）薄膜或者PET（聚酯）薄膜，厚度为0.11-0.36mm，接触层为PE（聚乙烯）纤维；
所述的发泡模具、成型模具在填入发泡原料之前可涂覆有机硅脱模剂，亦可选择其他有机脱模剂或无机脱模剂。
实施例一：
以本发明加工鞋垫时，选取曲面鞋垫形状的模具，并选取以下发泡及成型原料：
1）进行发泡的发泡体原料为：聚氨酯树脂原料（发泡基材）、软质PVC与EVA混合余料（软泡废料）、发泡剂、催化剂和稳定剂；发泡时预热后恒定温度为120℃，发泡时间为13min；挤塑成型时，加压合模的成型时间为9h；
2）进行贴合的其余结构层为：耐磨橡胶基底层、TPU膜弹性层、PE纤维接触层、PVC薄膜防尘外膜；
3）通过所述的加工工艺以完成选模-发泡-定型-贴合的整体过程，以得到复合结构的鞋垫。
实施例二：
以本发明加工坐垫时，选取平面或者弧面坐垫形状的模具，并选取以下发泡及成型原料：
1）进行发泡的发泡体原料为：EVA树脂原料（发泡基材）、软质PVC与聚氨酯边角料（软泡废料）、发泡剂、催化剂、填充剂和调节剂；发泡时预热后恒定温度为126℃，发泡时间为17min；挤塑成型时，加压合模的成型时间为11h；
2）进行贴合的其余结构层为：耐磨橡胶基底层、PU膜弹性层、PE纤维接触层、PET薄膜防尘外膜；
3）通过所述的加工工艺以完成选模-发泡-定型-贴合的整体过程，以得到复合结构的鞋垫。
以上所述，仅是本发明的较佳实施例，并非对本发明的技术范围作任何限制，本行业的技术人员，在本技术方案的启迪下，可以做出一些变形与修改，凡是依据本发明的技术实质对以上的实施例所作的任何修改、等同变化与修饰，均仍属于本发明技术方案的范围内。

Claims (6)

1.一种采用真空贴合的弹性复合体加工工艺，其特征在于，所述弹性复合体加工工艺主要包括以下步骤：
1）弹性复合体结构设定：所述弹性复合体的结构层包括基底层、发泡体、热熔胶涂布层、弹性层、接触层和防尘外膜；
2）选取模具：选取铝合金模具为弹性复合体中发泡体的发泡及成型的模具，发泡模具为不定型的发泡室，发泡模具在其上模、下模分别开设间隔排列的通气小孔，孔直径为0.4-0.7mm，孔间距为25-30mm；成型模具为曲面鞋垫、曲面护具或者弧面护套形状，亦或者立体片材、板材、型材形状，发泡体通过选取的成型模具选择性成型为所需形状；
3）发泡成型：首先在发泡模具中填入搅碎且搅拌均匀的发泡原料，主要包括发泡基材、软泡废料、发泡剂、催化剂和其余发泡辅料，合模后将发泡模具放置在发泡蒸箱内并通入蒸汽进行发泡，所通入的蒸汽压力为0.5-0.8MPa，然后采用60-80℃的温度预热40s，预热完成后升温至116-126℃进行加热，加热时间为9-18min，发泡原料受热软化并且发泡膨胀，逐渐形成熔融状态的熔结体；然后将发泡熔结体挤塑到成型模具中，模具合模后加压定型并且静置成型8-12h，冷却脱模后取出已定型的待用发泡体；
4）叠置贴合：弹性复合体的结构层由下至上依次为基底层、发泡体、弹性层和接触层，两结构层之间涂覆热熔胶涂布层，并以防尘外膜包围覆盖在整体的外表面；进行叠置贴合时，将基底层、发泡体、弹性层和接触层通过热熔胶涂布层依次逐层初步贴合为所述弹性复合体；
5）真空紧密贴合：将步骤4）初步贴合的弹性复合体转移至真空贴合机中进行紧密贴合，真空贴合机采用的贴合模具为可加热的抽真空铝板，通过模具的上模、下模形成封闭的真空贴合区，所述的弹性复合体在完成初步贴合时，结构层之间由于溶胶厚积不均或者贴合不均匀而存在凹凸不均的溶胶层，以及结构层之间由于贴合不紧而产生气泡；将弹性复合体置于抽真空贴合区内，通过抽真空作用将弹性复合体的结构层之间存在的气泡抽除，使得贴合紧密，同时通过抽真空及加热作用：加热方式为先预热后逐渐升温，温度控制范围为32-220℃，以将结构层连接产生的凹凸不均的溶胶层抚平，从而使得弹性复合体表面整齐并能完成塑型；
6）密封储存：将两薄片防尘外膜铺设在步骤5）的弹性复合体的上下表面，防尘外膜的表面积比弹性复合体表面积大，两防尘外膜超出弹性复合体边缘的部分为粘合区，通过热压合粘合区形成防尘防水的密封整体。
2.根据权利要求1所述的一种采用真空贴合的弹性复合体加工工艺，其特征在于，所述发泡原料的原料组分主要包括：发泡基材66-73份、软泡废料19-26份、发泡剂0.51-0.71份、催化剂0.36-1.20份和其余发泡辅料0.50-1.50份，其余发泡辅料主要由稳定剂、填充剂、调节剂组成。
3.根据权利要求2所述的一种采用真空贴合的弹性复合体加工工艺，其特征在于，所述的发泡基材为可发性EPS原料、PVC树脂原料、聚氨酯树脂原料或EVA树脂原料。
4.根据权利要求2所述的一种采用真空贴合的弹性复合体加工工艺，其特征在于，所述的软泡废料为橡胶碎料、聚氨酯边角料、软质PVC废料或EVA余料，或者混合余料。
5.根据权利要求1所述的一种采用真空贴合的弹性复合体加工工艺，其特征在于，所述弹性复合体的基底层为耐磨橡胶，弹性层为TPU膜或者PU膜、弹性布料，厚度为1.2-2.1mm；防尘外膜为PVC薄膜或者PET薄膜，厚度为0.11-0.36mm，接触层为PE纤维。
6.根据权利要求1所述的一种采用真空贴合的弹性复合体加工工艺，其特征在于，所述的发泡模具、成型模具在填入发泡原料之前可涂覆有机硅脱模剂。
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