CN107253360A - 一种发泡改良块状软底地毯及其制备方法 - Google Patents
一种发泡改良块状软底地毯及其制备方法 Download PDFInfo
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Abstract
本发明公开了一种发泡改良块状软底地毯,该地毯从上到下依次为坯毯层、EVA预涂胶层、上层PVC胶层、玻璃丝布和下层发泡PVC胶层,同时公开了该地毯的制备工艺,包括先将EVA预涂胶涂到坯毯层背面,烘干固化制得有预涂层的坯毯;然后将上层PVC胶与下层发泡PVC胶层,通过胶方配比及工艺参数的设计,并在其中加入玻璃丝布后,与有预涂层的坯毯复合压实,进烘箱塑化反应成型,制得方块地毯。本发明所公开的地毯制备工艺可以减少原材料的大量使用,增强产品弹性性能,提升传统PVC方块地毯品质,增强传统产品竞争力。
Description
技术领域
本发明属于地毯生产技术领域,尤其涉及一种块状节能环保、发泡改良PVC块状软底地毯及其制备方法。
背景技术
根据供应的款式不同,地毯可分为整幅卷装地毯和方块地毯,方块地毯搬运、铺设灵活,且可随时更换磨损严重部位的地毯。
方块地毯主要有沥青底、PVC底及PU底。沥青底档次较低,价格便宜。PU底地毯弹性好,脚感柔软舒适,同时具有保温降噪性能,但价格比较高,目前市场份额占比较低。占据市场主导地位的是传统PVC地毯。而PVC地毯,存在无弹性,脚感硬,保温降噪性能明显不如PU产品;同时重量重,每平方米重量通常在5000g/㎡,带来生产原材料及成品运输、施工搬运是一项十分繁重的工作;特别是占比在50~65%的主要填料碳酸钙更是大进大出,同时带来山体、矿山的大量开采,带来粉尘污染、高耗能等不利环境因素。
现在软底地毯主要有两种,PU软底和仿PU的厚烟灰底布软底地毯两种。
公布号CN102920295B的中国发明专利公布了一种块状PU软底地毯的制备方法,其制备具体情况是:在烟灰无纺布上涂两层PU胶,并在其中间添加玻璃丝布,之后与已预涂的坯毯复合压实,进烘箱固化反应。为了增强其防水性能,以适于方块地毯的先切块后印花工艺,在预涂工艺中添加硅酸盐类物质以达到阻水易烘干的目的。是一款高档产品,但因PU成本原因,销售价格较高。
公布号CN1062264022A公布了一种仿PU软底地毯的制备方法,其制备具体情况是:在厚烟灰底布涂一层环保胶,与已预涂的坯毯复合压实,进烘箱烘干固化制得。为了解决尺寸稳定性及翘曲等品质问题,对烟灰底布生产工艺、使用方式及预涂工艺进行了全面改进。但在生产中控制要求会相对较高,且因为水份挥发烘干不易,会存在生产效率偏低状况。
发明内容
为解决上述技术问题,本发明提供了一种发泡改良块状软底地毯及其制备方法,以达到减少原材料的大量使用,增强产品弹性性能,提升传统PVC方块地毯品质,增强传统产品竞争力的目的。
为达到上述目的,本发明的技术方案如下:
一种发泡改良块状软底地毯,该地毯从上到下依次为坯毯层、EVA预涂胶层、上层PVC胶层、玻璃丝布和下层发泡PVC胶层。
上述方案中,所述EVA预涂胶层由乙烯-醋酸乙烯酯共聚物30~50重量份、碳酸钙30~50重量份、辅料1~2重量份、水10~20重量份制成,碳酸钙325目。
上述方案中,所述上层PVC胶层由聚氯乙烯糊树脂10~18重量份、增塑剂10~18重量份、碳酸钙50~65重量份、硬脂酸类PVC增强剂2~5重量份、辅料1~5重量份制成,碳酸钙120目。
上述方案中,所述下层发泡PVC胶层由聚氯乙烯糊树脂10~18重量份、增塑剂10~18重量份、发泡剂0.1~0.9重量份、橡胶类PVC发泡体弹性增韧剂0.5~1重量份、碳酸钙50~65重量份、硬脂酸类PVC增强剂2~5重量份、辅料1~5重量份制成,碳酸钙120目。
进一步的技术方案中,所述EVA预涂胶层所用辅料包括交联剂,另外还包括渗透剂、分散剂、发泡剂和增稠剂中的一种或多种的组合,该辅料的作用是改善提高EVA胶的性能及预涂上胶后坯毯性能。
进一步的技术方案中,所述上层PVC胶层、下层发泡PVC胶层所用辅料为去水剂、PVC稳定剂、染料碳黑和降粘剂的组合。
一种发泡改良块状软底地毯的制备方法,包括如下步骤:
(1)将发泡后的EVA预涂胶涂覆于坯毯层背面,加热反应后,得到有预涂层的坯毯;
(2)将添加有发泡剂0.1~0.9重量份、橡胶类PVC发泡体弹性增韧剂0.5~1重量份混合搅拌均匀的PVC胶液涂覆到有铁氟龙涂层的传送带上,得到下层发泡PVC胶层,并在其上贴覆一层玻璃丝布;
(3)在下层发泡PVC胶层和玻璃丝布上,再涂覆上层PVC胶层;
(4)涂覆好上层PVC胶层后,将有EVA预涂层预烘收缩完全的坯毯与之辊压,进入烘箱加热塑化反应后,经裁断机冲切即得块状地毯,再经检验、装箱、码垛后入库。
进一步的技术方案中,所述步骤(1)中,加热反应的温度为130~170℃;所述步骤(4)中,加热塑化前段烘箱温度为150~160℃,后段烘箱温度为180~185℃,且保证在烘箱左中右部分温度均匀一致;辊压经复合辊和挤压辊进行辊压。
进一步的技术方案中,所述步骤(2)中,下层发泡PVC胶层的粘度为50000~70000CPS;步骤(3)中,上层PVC胶层的粘度在40000~50000CPS。
通过上述技术方案,本发明提供的发泡改良块状软底地毯具有以下有益效果:
1、在现有技术中,普通PVC方块地毯的毯背毫无弹性,并且在使用中不能象满幅地毯在下面铺设地毯弹性脚垫,所以方块地毯的脚感差。本发明的地毯,增加了地毯的弹性,脚感舒适。
2、在现有技术中,普通PVC方块地毯重量大,在5000克/平左右,通过发泡技术,可有效减轻25%的重量,节能降耗,减少了原材料的消耗浪费,降低了运输成本,减轻生产工人和铺设工人的劳动强度。
3、在增加地毯弹性的同时,可有效提高地毯保温、降噪功能,提高了产品的内在品质,赋予其新的功能性。
4、通过设备控制、工艺参数设计、胶方配比,很好地实现方块地毯的发泡生产,有效保障产品各项指标符合国家标准要求,并有效保证实际使用中拼接和使用要求。
附图说明
为了更清楚地说明本发明实施例或现有技术中的技术方案,下面将对实施例或现有技术描述中所需要使用的附图作简单地介绍。
图1为本发明实施例所公开的一种发泡改良块状软底地毯结构示意图。
图中:1、坯毯层;2、EVA预涂胶层;3、上层PVC胶层;4、玻璃丝布;5、下层发泡PVC胶层。
具体实施方式
下面将结合本发明实施例中的附图,对本发明实施例中的技术方案进行清楚、完整地描述。
本发明提供了一种发泡改良块状软底地毯,如图1所示,从上到下依次包括坯毯层1、EVA预涂胶层2、上层PVC胶层3、玻璃丝布4和下层发泡PVC胶层5。其中,上层PVC胶层3也可以选择发泡工艺进行制备,工艺同下层发泡PVC胶层5。
实施例1:
将42重量份的乙烯-醋酸乙烯酯共聚物、45重量份的碳酸钙(325目)、2重量份的辅料、与12重量份的水混合,得到预涂用EVA胶,辅料为渗透剂、分散剂、发泡剂和胶联剂的组合。
将得到的预涂用EVA胶进行发泡后,涂覆于坯毯的背面(其中坯毯即簇绒绒头植于无纺布上制得),用刮刀刮平后,置于烘箱中150℃进行固化反应并烘干,得到有预涂层的坯毯,其预涂胶层涂敷干胶重550克/平,下机幅宽2.06米(对应于产品50厘米*4块的幅宽要求)。
将10重量份的聚氯乙烯糊树脂、12重量份的增塑剂、0.3重量份的发泡剂、0.9重量份的橡胶类PVC发泡体弹性增韧剂、65重量份的碳酸钙、3重量份的硬脂酸类PVC增强剂、4重量份的辅料混合而成的PVC胶液搅拌均匀涂覆到有铁氟龙涂层的传送带上,得到下层发泡PVC胶层,涂覆重量1000g/㎡,并在其上贴覆一层玻璃丝布,玻璃丝布规格40g/㎡。辅料为去水剂、PVC稳定剂、染料碳黑和降粘剂的组合。
在下层发泡PVC胶层和玻璃丝布上,再涂覆上层PVC胶层,涂覆重量1100g/㎡。上层PVC胶层由聚氯乙烯糊树脂12重量份、增塑剂16重量份、碳酸钙55重量份、硬脂酸类PVC增强剂2重量份、辅料5重量份制成,碳酸钙120目。辅料为去水剂、PVC稳定剂、染料碳黑和降粘剂的组合。
涂覆好上层PVC胶层后,将有EVA预涂层预烘收缩完全的坯毯与之辊压,进入烘箱加热塑化反应,塑化温度为185℃,出来烘箱后,输入裁断机冲切制得块状地毯。再经检验、装箱、码垛后入库。
实施例2:
将43重量份的乙烯-醋酸乙烯酯共聚物、42重量份的碳酸钙(325目)、2重量份的辅料、与10重量份的水混合,得到预涂用EVA胶,辅料为渗透剂、增稠剂、发泡剂和胶联剂的组合。
将得到的预涂用EVA胶进行发泡后,涂覆于坯毯的背面(其中坯毯即簇绒绒头植于无纺布上制得),用刮刀刮平后,置于烘箱中152℃进行固化反应并烘干,得到有预涂层的坯毯,其预涂胶层涂敷干胶重500克/平,下机幅宽2.05米(对应于产品50厘米*4块的幅宽要求)。
将16重量份的聚氯乙烯糊树脂、10重量份的增塑剂、0.25重量份的发泡剂、0.8重量份的橡胶类PVC发泡体弹性增韧剂、50重量份的碳酸钙、5重量份的硬脂酸类PVC增强剂、2重量份的辅料混合而成的PVC胶液搅拌均匀涂覆到有铁氟龙涂层的传送带上,得到下层发泡PVC胶层,涂覆重量1050g/㎡,并在其上贴覆一层玻璃丝布,玻璃丝布规格40g/㎡。辅料为去水剂、PVC稳定剂、染料碳黑和降粘剂的组合。
在下层发泡PVC胶层和玻璃丝布上,再涂覆上层PVC胶层,涂覆重量1000g/㎡。上层PVC胶层由聚氯乙烯糊树脂18重量份、增塑剂12重量份、碳酸钙60重量份、硬脂酸类PVC增强剂4重量份、辅料3重量份制成,碳酸钙120目。辅料为去水剂、PVC稳定剂、染料碳黑和降粘剂的组合。
涂覆好上层PVC胶层后,将有EVA预涂层预烘收缩完全的坯毯与之辊压,进入烘箱加热塑化反应,塑化温度为187℃,出来烘箱后,输入裁断机冲切制得块状地毯。再经检验、装箱、码垛后入库。
实施例3:
将45重量份的乙烯-醋酸乙烯酯共聚物、40重量份的碳酸钙(325目)、2重量份的辅料、与10重量份的水混合,得到预涂用EVA胶,辅料为渗透剂、分散剂、发泡剂和胶联剂的组合。
将得到的预涂用EVA胶进行发泡后,涂覆于坯毯的背面(其中坯毯即簇绒绒头植于无纺布上制得),用刮刀刮平后,置于烘箱中148℃进行固化反应并烘干,得到有预涂层的坯毯,其预涂胶层涂敷干胶重570克/平,下机幅宽2.045米(对应于产品50厘米*4块的幅宽要求)。
将10重量份的聚氯乙烯糊树脂、16重量份的增塑剂、0.4重量份的发泡剂、1.0重量份的橡胶类PVC发泡体弹性增韧剂、60重量份的碳酸钙、4重量份的硬脂酸类PVC增强剂、1重量份的辅料混合而成的PVC胶液搅拌均匀涂覆到有铁氟龙涂层的传送带上,得到下层发泡PVC胶层,涂覆重量850g/㎡,并在其上贴覆一层玻璃丝布,玻璃丝布规格40g/㎡。辅料为去水剂、PVC稳定剂、染料碳黑和降粘剂的组合。
在下层发泡PVC胶层和玻璃丝布上,再涂覆上层PVC胶层,涂覆重量1050g/㎡。上层PVC胶层由聚氯乙烯糊树脂10重量份、增塑剂18重量份、碳酸钙50重量份、硬脂酸类PVC增强剂3重量份、辅料1重量份制成,碳酸钙120目。辅料为去水剂、PVC稳定剂、染料碳黑和降粘剂的组合。
涂覆好上层PVC胶层后,将有EVA预涂层预烘收缩完全的坯毯与之辊压,进入烘箱加热塑化反应,塑化温度为182℃,出来烘箱后,输入裁断机冲切制得块状地毯。再经检验、装箱、码垛后入库。
对比例1:
将40重量份的乙烯-醋酸乙烯酯共聚物、45重量份的碳酸钙(325目)、2重量份的辅料、与10重量份的水混合,得到预涂用EVA胶,辅料为渗透剂、分散剂、发泡剂和胶联剂的组合。
将得到的预涂用EVA胶进行发泡后,涂覆于坯毯的背面(其中坯毯即簇绒绒头植于无纺布上制得),用刮刀刮平后,置于烘箱中145℃进行固化反应并烘干,得到有预涂层的坯毯,其预涂胶层涂敷干胶重560克/平,下机幅宽2.05米(对应于产品50厘米*4块的幅宽要求)。
将10重量份的聚氯乙烯糊树脂、16重量份的增塑剂、0.3重量份的发泡剂、60重量份的碳酸钙、4重量份的硬脂酸类PVC增强剂、1重量份的辅料混合而成的PVC胶液搅拌均匀涂覆到有铁氟龙涂层的传送带上,得到下层发泡PVC胶层,涂覆重量980g/㎡,并在其上贴覆一层玻璃丝布,玻璃丝布规格40g/㎡。辅料为去水剂、PVC稳定剂、染料碳黑和降粘剂的组合。此处不再添加橡胶类PVC发泡体弹性增强剂。
在下层发泡PVC胶层和玻璃丝布上,再涂覆上层PVC胶层,涂覆重量950g/㎡。上层PVC胶层由聚氯乙烯糊树脂15重量份、增塑剂15重量份、碳酸钙55重量份、硬脂酸类PVC增强剂3重量份、辅料1重量份制成,碳酸钙120目。辅料为去水剂、PVC稳定剂、染料碳黑和降粘剂的组合。
涂覆好上层PVC胶层后,将有EVA预涂层预烘收缩完全的坯毯与之辊压,进入烘箱加热塑化反应,塑化温度为185℃,出来烘箱后,输入裁断机冲切制得块状地毯。再经检验、装箱、码垛后入库。
对上述制得的块状地毯,进行相关测试,结果见表1。
表1块状地毯的翘曲值、弹性变形对比
实施例1 | 实施例2 | 实施例3 | 对比例1 | |
翘曲值(mm) | 1.2 | 0.8 | 1.3 | 1.0 |
弹性变形(%) | 41 | 38 | 45 | 25 |
重量减少(%) | 27 | 25 | 30 | 17 |
边与中间厚度差(mm) | 0厚度一致 | 0厚度一致 | 0厚度一致 | 0.15中间薄 |
实验结果表明,本发明的三个实施例制备的块状地毯重量大幅减少,弹性明显增加,各项主要指标完全达到国家标准。在对比例1中,未加入橡胶类PVC发泡体弹性增强剂,影响很明显,发泡效果不理想。
对所公开的实施例的上述说明,使本领域专业技术人员能够实现或使用本发明。对这些实施例的多种修改对本领域的专业技术人员来说将是显而易见的,本文中所定义的一般原理可以在不脱离本发明的精神或范围的情况下,在其它实施例中实现。因此,本发明将不会被限制于本文所示的这些实施例,而是要符合与本文所公开的原理和新颖特点相一致的最宽的范围。
Claims (9)
1.一种发泡改良块状软底地毯,其特征在于,该地毯从上到下依次为坯毯层、EVA预涂胶层、上层PVC胶层、玻璃丝布和下层发泡PVC胶层。
2.根据权利要求1所述的一种发泡改良块状软底地毯,其特征在于,所述EVA预涂胶层由乙烯-醋酸乙烯酯共聚物30~50重量份、碳酸钙30~50重量份、辅料1~2重量份、水10~20重量份制成,碳酸钙325目。
3.根据权利要求1所述的一种发泡改良块状软底地毯,其特征在于,所述上层PVC胶层由聚氯乙烯糊树脂10~18重量份、增塑剂10~18重量份、碳酸钙50~65重量份、硬脂酸类PVC增强剂2~5重量份、辅料1~5重量份制成,碳酸钙120目。
4.根据权利要求1所述的一种发泡改良块状软底地毯,其特征在于,所述下层发泡PVC胶层由聚氯乙烯糊树脂10~18重量份、增塑剂10~18重量份、发泡剂0.1~0.9重量份、橡胶类PVC发泡体弹性增韧剂0.5~1重量份、碳酸钙50~65重量份、硬脂酸类PVC增强剂2~5重量份、辅料1~5重量份制成,碳酸钙120目。
5.根据权利要求2所述的一种发泡改良块状软底地毯,其特征在于,所述EVA预涂胶层所用辅料包括交联剂,另外还包括渗透剂、分散剂、发泡剂和增稠剂中的一种或多种的组合。
6.根据权利要求3或4所述的一种发泡改良块状软底地毯,其特征在于,所述上层PVC胶层、下层发泡PVC胶层所用辅料为去水剂、PVC稳定剂、染料碳黑和降粘剂的组合。
7.一种发泡改良块状软底地毯的制备方法,其特征在于,包括如下步骤:
(1)将发泡后的EVA预涂胶涂覆于坯毯层背面,加热反应后,得到有预涂层的坯毯;
(2)将添加有发泡剂0.1~0.9重量份、橡胶类PVC发泡体弹性增韧剂0.5~1重量份混合搅拌均匀的PVC胶液涂覆到有铁氟龙涂层的传送带上,得到下层发泡PVC胶层,并在其上贴覆一层玻璃丝布;
(3)在下层发泡PVC胶层和玻璃丝布上,再涂覆上层PVC胶层;
(4)涂覆好上层PVC胶层后,将有EVA预涂层预烘收缩完全的坯毯与之辊压,进入烘箱加热塑化反应后,经裁断机冲切即得块状地毯,再经检验、装箱、码垛后入库。
8.根据权利要求7所述的一种发泡改良块状软底地毯的制备方法,其特征在于,所述步骤(1)中,加热反应的温度为130~170℃;所述步骤(4)中,加热塑化前段烘箱温度为150~160℃,后段烘箱温度为180~185℃,且保证在烘箱左中右部分温度均匀一致;辊压经复合辊和挤压辊进行辊压。
9.根据权利要求7所述的一种发泡改良块状软底地毯的制备方法,其特征在于,所述步骤(2)中,下层发泡PVC胶层的粘度为50000~70000CPS;步骤(3)中,上层PVC胶层的粘度在40000~50000CPS。
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