CN109130399A - 一种高耐磨橡胶地垫及其制备方法 - Google Patents
一种高耐磨橡胶地垫及其制备方法 Download PDFInfo
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- CN109130399A CN109130399A CN201810570802.4A CN201810570802A CN109130399A CN 109130399 A CN109130399 A CN 109130399A CN 201810570802 A CN201810570802 A CN 201810570802A CN 109130399 A CN109130399 A CN 109130399A
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Abstract
本发明公开了一种高耐磨橡胶地垫及其制备方法,该橡胶地垫由底层和面层贴合而成,所述底层由废旧橡胶颗粒粘结而成,所述面层由耐磨橡胶颗粒粘结而成,且面层中分散有增强纤维;所述耐磨橡胶颗粒由三元乙丙橡胶、炭黑、白炭黑、氮‑磷复配阻燃剂、纳米蒙脱石粉、氧化锌、抗氧剂、紫外线吸收剂、防霉抗菌剂、促进剂、橡胶油和色粉组成。其制备过程如下:1)底层的制作;2)耐磨橡胶颗粒的制作;3)面层的制作;4)面层和底层的贴合。本发明的橡胶地垫表面强度高、耐磨性好、弹性大,且阻燃抗菌,不易脱色、脱粒和变形起翘,制备工艺简单,生产成本低,便于进行大规模推广应用。
Description
技术领域
本发明涉及一种高耐磨橡胶地垫及其制备方法,属于橡胶工业技术领域。
背景技术
橡胶地垫,是指由天然橡胶、合成橡胶和其它成分的高分子材料制成的地垫,一般设置在浴室、厨房、健身房、幼儿园、运动场、公园、游乐场等处,具有保持地面整洁、防滑、减震等作用。目前,市售橡胶地垫的面层(或整体)大多是由橡胶颗粒经胶粘剂粘合而成,而橡胶颗粒本身的强度较低、耐磨性差、易破损,由橡胶颗粒粘合而成的面层在外力作用下很容易出现区域性的破损脱落,橡胶地垫的耐磨性普遍较差,后期的维修成本高,限制了其大规模推广应用。
因此,有必要开发一种表面耐磨性好、强度高的橡胶地垫。
发明内容
本发明的目的在于提供一种高耐磨橡胶地垫及其制备方法。
本发明所采取的技术方案是:
一种高耐磨橡胶地垫,由底层和面层贴合而成,所述底层由废旧橡胶颗粒粘结而成,所述面层由耐磨橡胶颗粒粘结而成,且面层中分散有增强纤维;所述耐磨橡胶颗粒由以下质量份的组分组成:三元乙丙橡胶:100份;炭黑:40~60份;白炭黑:25~35份;氮-磷复配阻燃剂:10~20份;纳米蒙脱石粉:4~8份;氧化锌:3~7份;抗氧剂:3~7份;紫外线吸收剂:3~7份;防霉抗菌剂:2~5份;促进剂:5~10份;橡胶油:20~40份;色粉:15~25份。
所述面层的厚度为2~8mm,所述底层的厚度为5~15mm。
所述增强纤维为聚酯纤维、芳纶纤维、尼龙纤维、棉纤维中的至少一种,长度为2~3mm。
所述耐磨橡胶颗粒、增强纤维的质量比为1:(0.02~0.05)。
所述氮-磷复配阻燃剂为多聚磷酸铵和三嗪类化合物的复配物,且多聚磷酸铵和三嗪类化合物均用硅烷偶联剂进行过表面处理。
所述纳米蒙脱石粉为硅烷偶联剂改性的纳米蒙脱石粉。
所述抗氧剂为抗氧剂456、抗氧剂TPM中的至少一种。
所述紫外线吸收剂为2-羟基-4-正辛氧基二苯甲酮、2-(2′-羟基-3′,5′-二叔苯基)-5-氯化苯并三唑、2-(2′-羟基-5′-甲基苯基)苯并三氮唑、2,4-二羟基二苯甲酮中的至少一种。
所述防霉抗菌剂为苯并咪唑氨基甲酸甲酯、N′-(3,4-二氯苯基)-N,N-二甲基脲、1,2-苯并异噻唑啉-3-酮、1,2-苯并异噻唑啉-3-酮衍生物中的至少一种。
所述促进剂为噻唑类促进剂、秋兰姆类促进剂、次磺酰胺类促进剂、硫代甲酸盐类促进剂中的至少一种。
上述高耐磨橡胶地垫的制备方法,包括以下步骤:
1)底层的制作:将废旧橡胶颗粒和胶粘剂混合均匀,倒入模具中,在压强7~8MPa、温度160~180℃的条件下成型,得到底层;
2)耐磨橡胶颗粒的制作:将三元乙丙橡胶、炭黑、白炭黑、氮-磷复配阻燃剂、纳米蒙脱石粉、氧化锌、抗氧剂、紫外线吸收剂、防霉抗菌剂、促进剂、橡胶油和色粉加入密炼机,140~160℃的条件下进行混炼,再经开炼机开炼,将得到的胶片切割成胶条,再进行硫化、粉碎,得到耐磨橡胶颗粒;
3)面层的制作:将耐磨橡胶颗粒、增强纤维和胶粘剂混合均匀,倒入模具中,在压强10~15MPa、温度150~170℃的条件下成型,得到面层;
4)面层和底层的贴合:将底层放进模具中,表面涂上胶粘剂,再放上面层,在压强7~8MPa、温度160~180℃的条件下成型,得到高耐磨橡胶地垫。
本发明的有益效果是:本发明的橡胶地垫表面强度高、耐磨性好、弹性大,且阻燃抗菌,不易脱色、脱粒和变形起翘,制备工艺简单,生产成本低,便于进行大规模推广应用。
1)本发明的橡胶地垫中的面层和底层均是由橡胶颗粒胶结而成,地垫表面具有微凸的颗粒质感,不仅弹性大、减震效果好,而且防滑性能优异;
2)本发明的橡胶地垫的面层由耐磨橡胶颗粒组成,且面层中分散有增强纤维,面层的整体强度高,表面耐磨性好;
3)本发明的橡胶地垫阻燃和耐老化性能优异,不易变形,使用寿命长达5~8年,是传统橡胶地垫的2~3倍;
4)本发明的橡胶地垫中的底层以废旧橡胶颗粒为主要原料,实现了废旧橡胶的再生利用,不仅降低了橡胶地垫的生产成本,而且可以有效减少废旧橡胶引发的环境污染问题。
具体实施方式
一种高耐磨橡胶地垫,由底层和面层贴合而成,所述底层由废旧橡胶颗粒粘结而成,所述面层由耐磨橡胶颗粒粘结而成,且面层中分散有增强纤维;所述耐磨橡胶颗粒由以下质量份的组分组成:三元乙丙橡胶:100份;炭黑:40~60份;白炭黑:25~35份;氮-磷复配阻燃剂:10~20份;纳米蒙脱石粉:4~8份;氧化锌:3~7份;抗氧剂:3~7份;紫外线吸收剂:3~7份;防霉抗菌剂:2~5份;促进剂:5~10份;橡胶油:20~40份;色粉:15~25份。
优选的,所述面层的厚度为2~8mm,所述底层的厚度为5~15mm。
优选的,所述废旧橡胶颗粒的粒径为2~5mm。
优选的,所述耐磨橡胶颗粒的粒径为1~3mm。
优选的,所述增强纤维为聚酯纤维、芳纶纤维、尼龙纤维、棉纤维中的至少一种,长度为2~3mm。
优选的,所述耐磨橡胶颗粒、增强纤维的质量比为1:(0.02~0.05)。
优选的,所述氮-磷复配阻燃剂为多聚磷酸铵和三嗪类化合物的复配物,且多聚磷酸铵和三嗪类化合物均用硅烷偶联剂进行过表面处理。
优选的,所述纳米蒙脱石粉为硅烷偶联剂改性的纳米蒙脱石粉。
优选的,所述抗氧剂为抗氧剂456、抗氧剂TPM中的至少一种。
优选的,所述紫外线吸收剂为2-羟基-4-正辛氧基二苯甲酮、2-(2′-羟基-3′,5′-二叔苯基)-5-氯化苯并三唑、2-(2′-羟基-5′-甲基苯基)苯并三氮唑、2,4-二羟基二苯甲酮中的至少一种。
优选的,所述防霉抗菌剂为苯并咪唑氨基甲酸甲酯、N′-(3,4-二氯苯基)-N,N-二甲基脲、1,2-苯并异噻唑啉-3-酮、1,2-苯并异噻唑啉-3-酮衍生物中的至少一种。
优选的,所述促进剂为噻唑类促进剂、秋兰姆类促进剂、次磺酰胺类促进剂、硫代甲酸盐类促进剂中的至少一种。
上述高耐磨橡胶地垫的制备方法,包括以下步骤:
1)底层的制作:将废旧橡胶颗粒和胶粘剂混合均匀,倒入模具中,在压强7~8MPa、温度160~180℃的条件下成型,得到底层;
2)耐磨橡胶颗粒的制作:将三元乙丙橡胶、炭黑、白炭黑、氮-磷复配阻燃剂、纳米蒙脱石粉、氧化锌、抗氧剂、紫外线吸收剂、防霉抗菌剂、促进剂、橡胶油和色粉加入密炼机,140~160℃的条件下进行混炼,再经开炼机开炼,将得到的胶片切割成胶条,再进行硫化、粉碎,得到耐磨橡胶颗粒;
3)面层的制作:将耐磨橡胶颗粒、增强纤维和胶粘剂混合均匀,倒入模具中,在压强10~15MPa、温度150~170℃的条件下成型,得到面层;
4)面层和底层的贴合:将底层放进模具中,表面涂上胶粘剂,再放上面层,在压强7~8MPa、温度160~180℃的条件下成型,得到高耐磨橡胶地垫。
优选的,所述胶粘剂为氯乙烯树脂、醇酸树脂漆、间苯二酚、六次甲基四胺和白炭黑组成的组合物。
优选的,步骤1)所述废旧橡胶颗粒、胶粘剂的质量比为(8~10):1。
优选的,步骤1)所述废旧橡胶颗粒由回收的废旧橡胶经清洗、粉碎、除尘、除铁、过筛得到。
优选的,步骤3)所述耐磨橡胶颗粒、胶粘剂的质量比为(7~9):1。
下面结合具体实施例对本发明作进一步的解释和说明。
实施例1:
一种高耐磨橡胶地垫的制备方法如下:
1)底层的制作:将废旧橡胶颗粒(粒径2~3mm)和胶粘剂按照质量比8:1混合均匀,倒入模具中,在压强7MPa、温度170℃的条件下成型,得到底层(厚度为5mm);
2)耐磨橡胶颗粒的制作:将三元乙丙橡胶、炭黑、白炭黑、氮-磷复配阻燃剂、纳米蒙脱石粉、氧化锌、抗氧剂、紫外线吸收剂、防霉抗菌剂、促进剂、橡胶油和色粉加入密炼机,160℃的条件下进行混炼,再经开炼机开炼,将得到的胶片切割成胶条,再进行硫化、粉碎,得到耐磨橡胶颗粒(粒径1~2mm);
3)面层的制作:将耐磨橡胶颗粒、增强纤维和胶粘剂按照质量比8:0.24:1混合均匀,倒入模具中,在压强15MPa、温度160℃的条件下成型,得到面层(厚度为4mm);
4)面层和底层的贴合:将底层放进模具中,表面涂上胶粘剂,再放上面层,在压强7MPa、温度180℃的条件下成型,得到高耐磨橡胶地垫。
步骤2)所述耐磨橡胶颗粒的原料组成如下表所示:
表1耐磨橡胶颗粒的原料组成表
实施例2:
一种高耐磨橡胶地垫的制备方法如下:
1)底层的制作:将废旧橡胶颗粒(粒径3~4mm)和胶粘剂按照质量比8:1混合均匀,倒入模具中,在压强7MPa、温度180℃的条件下成型,得到底层(厚度为7mm);
2)耐磨橡胶颗粒的制作:将三元乙丙橡胶、炭黑、白炭黑、氮-磷复配阻燃剂、纳米蒙脱石粉、氧化锌、抗氧剂、紫外线吸收剂、防霉抗菌剂、促进剂、橡胶油和色粉加入密炼机,140℃的条件下进行混炼,再经开炼机开炼,将得到的胶片切割成胶条,再进行硫化、粉碎,得到耐磨橡胶颗粒(粒径1~2mm);
3)面层的制作:将耐磨橡胶颗粒、增强纤维和胶粘剂按照质量比7:0.35:1混合均匀,倒入模具中,在压强12MPa、温度160℃的条件下成型,得到面层(厚度为4mm);
4)面层和底层的贴合:将底层放进模具中,表面涂上胶粘剂,再放上面层,在压强7MPa、温度160℃的条件下成型,得到高耐磨橡胶地垫。
步骤2)所述耐磨橡胶颗粒的原料组成如下表所示:
表2耐磨橡胶颗粒的原料组成表
实施例3:
一种高耐磨橡胶地垫的制备方法如下:
1)底层的制作:将废旧橡胶颗粒(粒径3~4mm)和胶粘剂按照质量比9:1混合均匀,倒入模具中,在压强8MPa、温度170℃的条件下成型,得到底层(厚度为10mm);
2)耐磨橡胶颗粒的制作:将三元乙丙橡胶、炭黑、白炭黑、氮-磷复配阻燃剂、纳米蒙脱石粉、氧化锌、抗氧剂、紫外线吸收剂、防霉抗菌剂、促进剂、橡胶油和色粉加入密炼机,160℃的条件下进行混炼,再经开炼机开炼,将得到的胶片切割成胶条,再进行硫化、粉碎,得到耐磨橡胶颗粒(粒径2~3mm);
3)面层的制作:将耐磨橡胶颗粒、增强纤维和胶粘剂按照质量比7:0.28:1混合均匀,倒入模具中,在压强15MPa、温度150℃的条件下成型,得到面层(厚度为6mm);
4)面层和底层的贴合:将底层放进模具中,表面涂上胶粘剂,再放上面层,在压强8MPa、温度160℃的条件下成型,得到高耐磨橡胶地垫。
步骤2)所述耐磨橡胶颗粒的原料组成如下表所示:
表3耐磨橡胶颗粒的原料组成表
实施例4:
一种高耐磨橡胶地垫的制备方法如下:
1)底层的制作:将废旧橡胶颗粒(粒径4~5mm)和胶粘剂按照质量比9:1混合均匀,倒入模具中,在压强8MPa、温度160℃的条件下成型,得到底层(厚度为12mm);
2)耐磨橡胶颗粒的制作:将三元乙丙橡胶、炭黑、白炭黑、氮-磷复配阻燃剂、纳米蒙脱石粉、氧化锌、抗氧剂、紫外线吸收剂、防霉抗菌剂、促进剂、橡胶油和色粉加入密炼机,150℃的条件下进行混炼,再经开炼机开炼,将得到的胶片切割成胶条,再进行硫化、粉碎,得到耐磨橡胶颗粒(粒径1~2mm);
3)面层的制作:将耐磨橡胶颗粒、增强纤维和胶粘剂按照质量比8:0.16:1混合均匀,倒入模具中,在压强10MPa、温度170℃的条件下成型,得到面层(厚度为5mm);
4)面层和底层的贴合:将底层放进模具中,表面涂上胶粘剂,再放上面层,在压强8MPa、温度180℃的条件下成型,得到高耐磨橡胶地垫。
步骤2)所述耐磨橡胶颗粒的原料组成如下表所示:
表4耐磨橡胶颗粒的原料组成表
实施例5:
一种高耐磨橡胶地垫的制备方法如下:
1)底层的制作:将废旧橡胶颗粒(粒径4~5mm)和胶粘剂按照质量比8:1混合均匀,倒入模具中,在压强7MPa、温度160℃的条件下成型,得到底层(厚度为15mm);
2)耐磨橡胶颗粒的制作:将三元乙丙橡胶、炭黑、白炭黑、氮-磷复配阻燃剂、纳米蒙脱石粉、氧化锌、抗氧剂、紫外线吸收剂、防霉抗菌剂、促进剂、橡胶油和色粉加入密炼机,160℃的条件下进行混炼,再经开炼机开炼,将得到的胶片切割成胶条,再进行硫化、粉碎,得到耐磨橡胶颗粒(粒径2~3mm);
3)面层的制作:将耐磨橡胶颗粒、增强纤维和胶粘剂按照质量比9:0.27:1混合均匀,倒入模具中,在压强15MPa、温度170℃的条件下成型,得到面层(厚度为8mm);
4)面层和底层的贴合:将底层放进模具中,表面涂上胶粘剂,再放上面层,在压强8MPa、温度160℃的条件下成型,得到高耐磨橡胶地垫。
步骤2)所述耐磨橡胶颗粒的原料组成如下表所示:
表5耐磨橡胶颗粒的原料组成表
测试例:
1)缓冲性能、耐磨性能和阻燃性能测试:
对实施例1~5制备的橡胶地垫、市售橡胶地垫1(厚度为15mm)和市售橡胶地垫2(厚度为25mm)进行缓冲性能、耐磨性能和阻燃性能测试,测试结果如下表所示:
表6实施例1~5的橡胶地垫的性能测试数据
注:直角撕裂的测试标准为GB/T 529-2008。
由表6可知:实施例1~5的橡胶地垫的直角撕裂强度高,缓冲性能优异,耐磨和阻燃性能优异,直角撕裂性能、缓冲性能、耐磨性能和阻燃性能均显著优于市售橡胶地垫1和市售橡胶地垫2。
2)抗紫外线测试:
①紫外辐射暴露:
测试方法:ISO4982-3:2006,ISO 105-A02:1993Cor 2:2005。
测试条件:试验循环为ISO4982-3:2006循环1;灯管类型为UVA-340;光照:8h、60±3℃BST,0.76W/(m2·nm)@340nm;冷凝:4h、60±3℃BST。
测试结果:实施例1~5的橡胶地垫在连续暴露900h后,灰标等级为3,优于市售橡胶地垫1(灰标等级为1)和市售橡胶地垫2(灰标等级为2)。
②氙灯辐射暴露:
测试方法:ISO4982-3:2006和ISO 105-A02:1993Cor 2:2005。
测试条件:试验循环为ISO4982-3:2006循环1;辐照度:0.51±0.02W/(m2·nm)@340nm;光照:102min,黑标温度:65±3℃;相对湿度50±10%;光照和喷淋:18min;滤镜:Daylight。
根据ISO 105-A02,灰标等级是在标准光源D65下评定,5级最好,1级最差。中间查样和测试结束后的结果评定都是在上述指定的暴露周期后1小时内进行。
测试结果:实施例1~5的橡胶地垫在连续暴露1000h后,灰标等级为4,优于市售橡胶地垫1(灰标等级为2)和市售橡胶地垫2(灰标等级为2)。
综上所述:实施例1~5的橡胶地垫具有很好的抗紫外性能。
3)有害物质测试:
①对实施例1~5的橡胶地垫进行重金属镉、汞、六价铬测试,镉和汞的检测方法参考IEC62321:2008,ICP-OES,六价铬检测方法参考IEC 62321:2008,UV-Vis。
检测结果:未检出重金属镉、汞、六价铬。
②对实施例1~5的橡胶地垫进行溴联苯和溴二苯醚检测,检测方法参考IEC62321:2008,GC-MS。
检测结果:未检出溴联苯和溴二苯醚。
综上所述:对实施例1~5的橡胶地垫安全环保。
上述实施例为本发明较佳的实施方式,但本发明的实施方式并不受上述实施例的限制,其他的任何未背离本发明的精神实质与原理下所作的改变、修饰、替代、组合、简化,均应为等效的置换方式,都包含在本发明的保护范围之内。
Claims (10)
1.一种高耐磨橡胶地垫,其特征在于:由底层和面层贴合而成,所述底层由废旧橡胶颗粒粘结而成,所述面层由耐磨橡胶颗粒粘结而成,且面层中分散有增强纤维;所述耐磨橡胶颗粒由以下质量份的组分组成:三元乙丙橡胶:100份;炭黑:40~60份;白炭黑:25~35份;氮-磷复配阻燃剂:10~20份;纳米蒙脱石粉:4~8份;氧化锌:3~7份;抗氧剂:3~7份;紫外线吸收剂:3~7份;防霉抗菌剂:2~5份;促进剂:5~10份;橡胶油:20~40份;色粉:15~25份。
2.根据权利要求1所述的高耐磨橡胶地垫,其特征在于:所述面层的厚度为2~8mm,所述底层的厚度为5~15mm。
3.根据权利要求1所述的高耐磨橡胶地垫,其特征在于:所述增强纤维为聚酯纤维、芳纶纤维、尼龙纤维、棉纤维中的至少一种,长度为2~3mm。
4.根据权利要求1所述的高耐磨橡胶地垫,其特征在于:所述耐磨橡胶颗粒、增强纤维的质量比为1:(0.02~0.05)。
5.根据权利要求1所述的高耐磨橡胶地垫,其特征在于:所述氮-磷复配阻燃剂为多聚磷酸铵和三嗪类化合物的复配物,且多聚磷酸铵和三嗪类化合物均用硅烷偶联剂进行过表面处理。
6.根据权利要求1所述的高耐磨橡胶地垫,其特征在于:所述纳米蒙脱石粉为硅烷偶联剂改性的纳米蒙脱石粉。
7.根据权利要求1所述的高耐磨橡胶地垫,其特征在于:所述抗氧剂为抗氧剂456、抗氧剂TPM中的至少一种。
8.根据权利要求1所述的高耐磨橡胶地垫,其特征在于:所述紫外线吸收剂为2-羟基-4-正辛氧基二苯甲酮、2-(2′-羟基-3′,5′-二叔苯基)-5-氯化苯并三唑、2-(2′-羟基-5′-甲基苯基)苯并三氮唑、2,4-二羟基二苯甲酮中的至少一种。
9.根据权利要求1所述的高耐磨橡胶地垫,其特征在于:所述防霉抗菌剂为苯并咪唑氨基甲酸甲酯、N′-(3,4-二氯苯基)-N,N-二甲基脲、1,2-苯并异噻唑啉-3-酮、1,2-苯并异噻唑啉-3-酮衍生物中的至少一种;所述促进剂为噻唑类促进剂、秋兰姆类促进剂、次磺酰胺类促进剂、硫代甲酸盐类促进剂中的至少一种。
10.权利要求1~9中任意一项所述的高耐磨橡胶地垫的制备方法,其特征在于:包括以下步骤:
1)底层的制作:将废旧橡胶颗粒和胶粘剂混合均匀,倒入模具中,在压强7~8MPa、温度160~180℃的条件下成型,得到底层;
2)耐磨橡胶颗粒的制作:将三元乙丙橡胶、炭黑、白炭黑、氮-磷复配阻燃剂、纳米蒙脱石粉、氧化锌、抗氧剂、紫外线吸收剂、防霉抗菌剂、促进剂、橡胶油和色粉加入密炼机,140~160℃的条件下进行混炼,再经开炼机开炼,将得到的胶片切割成胶条,再进行硫化、粉碎,得到耐磨橡胶颗粒;
3)面层的制作:将耐磨橡胶颗粒、增强纤维和胶粘剂混合均匀,倒入模具中,在压强10~15MPa、温度150~170℃的条件下成型,得到面层;
4)面层和底层的贴合:将底层放进模具中,表面涂上胶粘剂,再放上面层,在压强7~8MPa、温度160~180℃的条件下成型,得到高耐磨橡胶地垫。
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