CN109098392A - 一种新型的橡塑运动地板及制备方法 - Google Patents

一种新型的橡塑运动地板及制备方法 Download PDF

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CN109098392A
CN109098392A CN201810647972.8A CN201810647972A CN109098392A CN 109098392 A CN109098392 A CN 109098392A CN 201810647972 A CN201810647972 A CN 201810647972A CN 109098392 A CN109098392 A CN 109098392A
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rubber
layer
floor
athletic floor
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金锋
周立杰
陈建军
李玉伶
刘洋
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Beijing Adt Product Of Rubber And Plastic Co Ltd
WEILAINSHUN PLASTIC PRODUCTS CO Ltd BEIJING
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Beijing Adt Product Of Rubber And Plastic Co Ltd
WEILAINSHUN PLASTIC PRODUCTS CO Ltd BEIJING
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Abstract

本发明公开了属于环保地板技术领域的一种新型的橡塑运动地板及制备方法。该橡塑运动地板由上至下包括橡胶耐磨层(1)、PVC耐压层(2‑1)、PVC稳定层(2‑2)、PVC弹性发泡层(2‑3)、PVC背封层(2‑4)；利用密炼、开炼、压延、硫化、打磨切边后得到橡胶耐磨层(1)，综合压延工艺、涂覆工艺和贴合装置制备PVC复合层(2)，最后利用界面剂将橡胶耐磨层(1)与PVC复合层(2)粘结得到的新型橡塑运动地板，同时具备橡胶地板、PVC运动地板的优点，克服了传统橡胶地板价格高昂、生产优质细密发泡气孔困难以及PVC运动地板存在强度低、不适用高强度场合、耐候性差、耐老化性能差、易变色、含增塑剂、长期使用增塑剂抽出等各种缺点。

Description

一种新型的橡塑运动地板及制备方法
技术领域
本发明属于环保地板技术领域，特别涉及一种新型的橡塑运动地板及制备方法。
背景技术
运动地板是指适用于铺装各种运动场所地面，以便更好的适用各种训练、竞技、锻炼、培训要求的专用地板。这类产品最大的优点是铺装过程简单、实用、便于清洁、养护，更能提供运动场所需要的各种运动性能及有效保护运动员的安全；广泛应用于如羽毛球、兵乓球、篮球、室内足球、多功能场馆、各类健身房、舞蹈房、学校、单位活动所、多功能厅、游乐园、幼儿园、商店、办公室、宾馆、医院的活动场地，甚至奥运会等各项国际性比赛中。
其中，PVC运动地板生产工艺相对成熟，可以生产发泡弹性型产品，价格便宜、便于安装施工、能满足运动场所需求，可制备的厚度为3.5mm-10mm；但是PVC运动地板存在易老化、使用寿命短、仅适用于使用强度要求较低的场所、受气温影响大、遇水遇雪发滑的缺点，且PVC运动地板含大量增塑剂，长期使用增塑剂抽出出现出油现象。
而橡胶地板主要铺设于地铁、高铁、机场等高人流量的场所以及高档会所、写字楼、等高级场所，不易老化使用寿命长，适用于使用强度要求高的场所，受气温影响小，遇水、遇雪不会打滑，且橡胶地板不含增塑剂，不会发生抽出现象；但是橡胶地板施工要求极高、价格高昂、生产工艺繁琐产量低、不易生产出发泡层以生产高厚度制品。
发明内容
本发明的目的在于提供一种新型的橡塑运动地板及制备方法，具体技术方案如下：
一种新型的橡塑运动地板由上至下包括橡胶耐磨层1、PVC复合层2；所述PVC复合层2由上至下依次包括PVC耐压层2-1、PVC稳定层2-2、PVC弹性发泡层2-3、PVC背封层2-4；
所述橡塑运动地板厚度为3.5mm～10mm，橡胶耐磨层1厚度为0.7mm～2.0mm。
所述橡胶耐磨层1与PVC复合层2通过单组分湿固化聚氨酯PUR热熔胶形成界面剂粘结。
所述单组分湿固化聚氨酯PUR热熔胶是单组份无溶剂100％固化活性物聚氨酯预聚物，加热150℃后该聚氨酯PUR由固体变为液体，并且具有流动性，在粘接橡胶耐磨层1与PVC复合层2时，借助于空气中存在的湿度和被粘物表面附着的湿气与之反应，交联形成惰性结构，生成具有高内聚力的高分子聚合物，在粘接物之间形成界面剂作用，反应交联后形成的界面剂具有耐高、低温特性，防水性能好、抗老化强并持久耐用的优点。
所述的橡塑运动地板的制备方法包括以下步骤：
(a)将橡胶、氧化锌、硬脂酸、抗氧剂、抗老化剂、硫磺促进剂、填充剂混合后，经密炼、开炼、压延、硫化、打磨切边后得到橡胶耐磨层1；
(b)以PVC、DOP、CaCO3、助剂、色料为原料，经混炼、压延分别制备PVC耐压层2-1、PVC背封层2-4；
(c)将玻璃纤维基材放置于涂覆工艺，将辊涂涂覆搅拌好的玻璃纤维糊料，经烘箱加热凝胶定型，得到PVC稳定层2-2；利用刀涂在PVC稳定层2-2上涂覆含有发泡剂的PVC糊料，并进入烘箱凝胶，得到PVC弹性发泡层2-3；
(d)利用加热轮加热贴合装置，分别将PVC背封层2-4与PVC弹性发泡层2-3贴合，将制备好的PVC耐压层2-1与PVC稳定层2-2上；置于发泡炉发泡，经底背加热压底花纹、冷却、收卷得到PVC复合层2；
(e)在PVC复合层2上表面即PVC耐压层2-1上涂辊界面剂，利用贴合加热加压装置将橡胶耐磨层1与PVC耐压层2-1紧密贴合，经冷却、裁边、收卷后即得到橡塑运动地板。
所述步骤(a)中橡胶为丁苯橡胶、三元乙丙橡胶、高苯乙烯橡胶中的一种或多种，填充剂为白炭黑、高岭土、碳酸钙中的一种或多种。
所述步骤(b)中PVC耐压层2-1厚度＞0.25mm，PVC背封层2-4厚度＜0.6mm。步骤(c)中PVC弹性发泡层2-3经2次涂覆、2次凝胶得到。
所述步骤(e)涂辊粘结剂后，应静置48小时，让液体聚氨酯PUR充分利用空气中湿度进行交联反应，形成界面剂。
本发明的有益效果为：本发明提供的新型的橡塑运动地板将橡胶地板、PVC运动地板的优点有效结合，拉伸强度远远大于纯PVC运动地板，可以达到5.0兆帕以上，耐磨性可以达到阿克隆磨耗值≤1.0，且成本低廉、易发泡，克服了橡胶地板价格高昂、生产优质细密发泡气孔困难以及PVC运动地板存在的各种缺点；制备工艺简单高效、易于工业化生产。
附图说明
图1为本发明提供了一种新型的橡塑运动地板制备工艺流程图；
图2为本发明提供了一种新型的橡塑运动地板结构示意图；
标号说明：1：橡胶耐磨层；2：PVC复合层；2-1：PVC耐压层；2-2：PVC稳定层；2-3：PVC弹性发泡层；2-4：PVC背封层。
具体实施方式
本发明提供了一种新型的橡塑运动地板及制备方法，下面结合具体实施方式对本发明做进一步的说明。
根据图1所示工艺流程图制备新型橡塑运动地板，包括以下步骤：
(1)制备橡胶耐磨层1
(1.1)按质量分数计，将95％的丁苯橡胶、三元乙丙橡胶、高苯乙烯橡胶中的一种或多种投入密炼机，回软1.5min，然后投入0.2％氧化锌、0.2％硬脂酸、0.2％抗氧剂、0.2％抗老化剂、0.2％硫磺促进剂加热120℃密炼2min，最后投入4％的白炭黑、高岭土、碳酸钙中的一种或多种作为补强填充材料；
(1.2)泄压，将密炼好的胶料排出并置于开炼机5分钟，下片，加入硫磺促进剂，下片标识停放，在常温条件下晾胶48小时，让其充分塑化；
(1.3)在90℃下，利用压延机将步骤(1.2)得到的胶料压延成型至所需尺寸，卷取后，送入鼓式硫化机，在高温高压下硫化2分钟，打磨、切边后得到厚度为0.7mm～2.0mm的橡胶耐磨层1。
(2)制备PVC复合层2
(2.1)以PVC、DOP、CaCO3、助剂、色料为原料，利用压延机通过压延工艺包括混炼、压延制备成连续片状半成品，冷却后根据厚度区别，分别制备厚度＞0.25mm的PVC耐压层2-1、厚度＜0.6mm的PVC背封层2-4，收卷备用；
(2.2)将玻璃纤维基材放置于涂覆工艺一段，将经过辊涂涂覆搅拌好的玻璃纤维糊料，经烘箱加热凝胶定型，得到PVC稳定层2-2；然后利用刀涂将制备好的含有发泡剂的PVC糊料涂覆在PVC稳定层2-2上，并进入烘箱凝胶，再重复一次涂覆、凝胶得到PVC弹性发泡层2-3；
(2.3)利用加热轮加热贴合装置将PVC背封层2-4与PVC弹性发泡层2-3贴合，贴合好后的半成品翻转后，利用加热轮加热贴合装置将制备好的PVC耐压层2-1贴合到PVC稳定层2-2上；然后置于发泡炉发泡，经底背加热压底花纹、冷却、收卷得到不含耐磨层的厚度为2.8mm-8.0mm的PVC复合层2。
PVC复合层2中PVC耐压层2-1起到抗压作用；PVC稳定层2-2使产品尺寸稳定、不收缩；PVC弹性发泡层2-3保证了产品的安全、回弹、吸震性，使得地板具有运动保护性能；PVC背封层2-4解决了产品背面平整度更易于铺装，PVC复合层2已经具备了PVC运动地板的优点即良好的发泡弹性、低廉的价格优势、稳定的尺寸性，但因没有PVC耐磨层，所以不具备耐磨损性。
(3)制备橡塑运动地板
将橡胶耐磨层1、PVC复合层2分别置于贴合机放料装置上，利用加热装置在150℃下先将固体的聚氨酯PUR预聚物加热，直至变为可流动性的液体，然后用空气泵打到两个涂胶钢轮之间，由钢轮传动并调整钢轮的间隙，让液体的聚氨酯流动；并将其涂辊在PVC复合层2的表面上即PVC耐压层2-1上以形成具有粘接作用的界面剂，待界面剂均匀后，利用贴合加热加压装置将橡胶耐磨层1与PVC耐压层2-1紧密贴合，经冷却、裁边、收卷后即得到3.5mm～10mm的橡塑运动地板。
上述得到的橡塑运动地板应静放48小时，让涂覆在两者之间的液体聚氨酯PUR充分利用空气中湿度进行反应，交联形成惰性结构，并具有高内聚力的高分子聚合物，从而形成界面剂起到完全粘接作用，并具有抗高、低温及粘牢度永久性。
一方面，由于运动地板需要对运动员有保护作用，运动地板厚度需要大于3.5mm，而传统橡胶地板制备工艺中，闭孔发泡效果差，易出现不均匀或大小不一等发泡问题，不易形成致密发泡气孔，且成本高昂；本发明利用PVC运动地板易发泡、低成本易加工的优点制备的3.5mm～10mm的橡塑运动地板则克服了传统橡胶地板的上述问题。
另一方面，利用界面剂的架桥作用，将非极性橡胶耐磨层1和强极性PVC复合层2有效结合，使橡胶地板代替原PVC运动地板的PVC耐磨层，保留原PVC运动地板的PVC耐压层、PVC弹性发泡层、PVC背封层，橡胶耐磨层可以加工各种压花、颜色、镶嵌图纹，使地板本身具有美观、防滑、耐划痕、耐磨损、遇水不滑、物理性能高的优点，可用于高强度场合，具备橡胶的耐老化、不变色、不含增塑剂、环保佳等一系列橡胶地板所具的特性，完全克服了用PVC做耐磨层的PVC运动地板的缺点即遇水发滑、受制于PVC本身强度低、不能适用高强度场合、耐候性、耐老化性能较差、易变色、含增塑剂、长期使用增塑剂抽出等，即地板既具备橡胶地板的特性优点，又具备PVC运动地板价廉优势，生产的厚度可达3.5mm-10mm，满足运动地板的需求。

Claims (6)

1.一种新型的橡塑运动地板，其特征在于，所述橡塑运动地板由上至下包括橡胶耐磨层(1)、PVC复合层(2)；所述PVC复合层(2)由上至下依次包括PVC耐压层(2-1)、PVC稳定层(2-2)、PVC弹性发泡层(2-3)、PVC背封层(2-4)；
所述橡塑运动地板厚度为3.5mm～10mm，橡胶耐磨层(1)厚度为0.7mm～2.0mm。
2.根据权利要求1所述的橡塑运动地板，其特征在于，所述橡胶耐磨层(1)与PVC复合层(2)通过聚氨酯PUR热熔胶形成界面剂粘结。
3.权利要求1或2所述的橡塑运动地板的制备方法，其特征在于，所述制备包括以下步骤：
(a)将橡胶、氧化锌、硬脂酸、抗氧剂、抗老化剂、硫磺促进剂、填充剂混合后，经密炼、开炼、压延、硫化、打磨切边后得到橡胶耐磨层(1)；
(b)以PVC、DOP、CaCO3、助剂、色料为原料，经混炼、压延分别制备PVC耐压层(2-1)、PVC背封层(2-4)；
(c)将玻璃纤维基材放置于涂覆工艺，将辊涂涂覆搅拌好的玻璃纤维糊料，经烘箱加热凝胶定型，得到PVC稳定层(2-2)；利用刀涂在PVC稳定层(2-2)上涂覆含有发泡剂的PVC糊料，并进入烘箱凝胶，得到PVC弹性发泡层(2-3)；
(d)利用加热轮加热贴合装置，分别将PVC背封层(2-4)与PVC弹性发泡层(2-3)贴合，将制备好的PVC耐压层(2-1)与PVC稳定层(2-2)上；置于发泡炉发泡，经底背加热压底花纹、冷却、收卷得到PVC复合层(2)；
(e)在PVC复合层(2)上表面即PVC耐压层(2-1)上涂辊界面剂，利用贴合加热加压装置将橡胶耐磨层(1)与PVC耐压层(2-1)紧密贴合，经冷却、裁边、收卷后即得到橡塑运动地板。
4.根据权利要求3所述的制备方法，其特征在于，所述步骤(a)中橡胶为丁苯橡胶、三元乙丙橡胶、高苯乙烯橡胶中的一种或多种，填充剂为白炭黑、高岭土、碳酸钙中的一种或多种。
5.根据权利要求3所述的制备方法，其特征在于，所述步骤(b)中PVC耐压层(2-1)厚度＞0.25mm，PVC背封层(2-4)厚度＜0.6mm。
6.根据权利要求3所述的制备方法，其特征在于，步骤(c)中PVC弹性发泡层(2-3)经2次涂覆、2次凝胶得到。
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Application publication date: 20181228