CN110448102B - 一种多层地垫及其制备工艺 - Google Patents
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Abstract
本发明公开了一种多层地垫及其制备工艺,多层地垫包括PVC层、PE层以及热塑性TPO层,PVC层和PE层的一面固定接合,热塑性TPO层和PE层的另一面固定接合;PVC层、PE层及热塑性TPO层的两端部通过高频压边以实现固定。制备工艺包括:获取PVC层步骤;获取PE层步骤;获取热塑性TPO层步骤;第一粘合步骤;第二粘合步骤;高频压边步骤。本发明同时具备了PVC发泡层的外观高级、触感柔软的优点以及PE发泡层重量轻、弹性好、造价低的优点,降低了地垫的边缘高度(包边厚度),使婴幼儿不容易因为地垫的边缘过高而发生摔倒、受伤。
Description
技术领域
本发明涉及家居用品领域,具体涉及一种多层地垫及其制备工艺。
背景技术
环保地垫、游戏垫多应用于婴幼儿活动的空间中,常覆盖在房间的地板上,供婴幼儿在上面爬行玩耍。由于其可以对温度过于冰凉的地板进行覆盖、对噪音进行隔离,同时自身柔软的特性能免于婴幼儿摔倒时发生磕碰受伤,现在已受到越来越多的家长青睐。
制作地垫通常会使用PVC发泡材料或PE发泡材料。PVC发泡层手感好,印刷、压纹等加工性及品质优异,很久之前就被广泛用于游戏垫及防止噪音地垫中,但因其原材料发泡率低重量大,移动和保管多有不便。与之相反,PE发泡层因重量小、弹性好、价格低被广泛使用,但其地面附着性和后期加工性(印刷及耐久性)、手感等都较差。
近来为了解决上述问题,会将两个产品结合开发,但现有技术多存在以下的缺点:PE层和PVC层结合后,边缘通常是采用织物进行缝纫包边,包边的厚度大,即地垫的边缘高度较高,使婴幼儿容易被绊倒摔跤。另外,织物也容易受到污染,难以进行清洗。
对异性物质层采用高频压边则可以解决包边厚度过大的问题。但是PE层的电流性很差,会因为电流产生热阻而熔断,因此直接对PVC层和PE进行高频压边也是不可行的。
另外,不同的材料层之间通常使用液体粘合剂进行粘合,干燥后会有溶剂残留,导致挥发性有机物(VOCs)和气味问题,影响婴儿的健康。
发明内容
为克服现有技术的不足,本发明的目的之一在于提供一种多层地垫,其结合了PVC发泡层、PE发泡层以及热塑性TPO层,采用高频压边使PVC发泡层、 PE发泡层和热塑性TPO层进行压边定形,降低了地垫的边缘高度。本发明的目的之二在于提供一种多层地垫的制备工艺,其用于制备上述的多层地垫。
本发明采用了以下的技术方案来实现:
一种多层地垫,包括:PVC层、PE层以及热塑性TPO层,所述PVC层和所述PE层的一面固定接合,所述热塑性TPO层和所述PE层的另一面固定接合; PVC层、PE层及热塑性TPO层的两端部通过高频压边以实现固定。进一步地,所述PVC层与所述PE层通过热塑性熔胶以实现粘合固定。
进一步地,所述热塑性TPO层与所述PE层通过热塑性熔胶以实现粘合固定。
进一步地,所述PVC层自上而下依次包括一体成型的未发泡表层、发泡层、粘合层和织物层,所述PVC层通过所述织物层与所述PE层接合固定。
进一步地,所述织物层为人造纤维或涤纶。
一种多层地垫的制备工艺,至少包括以下步骤:获取PVC层步骤:采用一般发泡制作方式获取所述PVC层;获取PE层步骤:采用一般发泡制作方式获取所述PE层;获取热塑性TPO层步骤:获取用于改善电流流动性的所述热塑性TPO层;第一粘合步骤:采用热塑性熔胶使所述PVC层中的织物层和所述 PE层的一面进行粘合固定,并通过热风进行吹干;第二粘合步骤:采用热塑性熔胶使所述热塑性TPO层和所述PE层的另一面进行粘合固定,并通过热风进行吹干:高频压边步骤:对高频压边机通入工作电流,通过高频压边机对所述PVC层、所述PE层和所述TPO层进行一定时间的高频压边定形,所述PE层会因高频电流所产生的电阻热而熔化断裂,所述PVC层和所述PE层实现压边定形。
进一步地,在所述第二粘合步骤和所述高频压边步骤之间,还包括剪裁步骤:按照规格所需要的大小,将粘合后的半成品地垫进行剪裁。
进一步地,在所述高频压边步骤中,对所述高频压边机通入的工作电流强度为3A及以上。
进一步地,在所述高频压边步骤中,高频压边的定形持续时间为2分钟及以上。
与现有技术相比,本发明能达到的有益效果是:PVC材料作为地垫的外层、 PE材料作为地垫的内层,使产品同时具备了PVC发泡层的外观高级、触感柔软、后期加工性好的优点以及PE发泡层重量轻、弹性好、造价低的优点,同时采用电流流动性强的热塑性TPO层进行高频压边,使PVC层、PE层和热塑性TPO 层可以紧密结合而不容易产生脱离,增强了地垫的地面附着性,降低了地垫的边缘高度(包边厚度),使婴幼儿不容易因为地垫的边缘过高而发生摔倒、受伤,且节省了现有技术中需要采用织布进行包边的材料成本,同时相比织布更不容易受到污染残留。
附图说明
图1为多层地垫的分解示意图;
图2为多层地垫的剖视图;
图3为图2的A处局部放大图;
图4为PVC层的分解示意图。
图中:10、PVC层;11、未发泡表层;12、发泡层;13、粘合层;14、织物层;20、PE层;30、热塑性TPO层。
具体实施方式
下面,结合附图以及具体实施方式,对本发明做进一步描述,需要说明的是,在不相冲突的前提下,以下描述的各实施例之间或各技术特征之间可以任意组合形成新的实施例。
需要说明的是,当元件被称为“固定于”另一个元件,它可以直接在另一个元件上或者也可以存在居中的元件。当一个元件被认为是“连接”另一个元件,它可以是直接连接到另一个元件或者可能同时存在居中元件。本文所使用的术语“垂直的”、“水平的”、“左”、“右”以及类似的表述只是为了说明的目的。术语“安装”、“相连”、“连接”应做广义理解,例如,可以固定连接,也可以是可拆卸连接,或一体地连接;可以是机械连接,也可以是电连接;可以是直接连接,也可以通过中间媒介间接相连,或是两个元件内部的连通。对于本领域的普通技术人员而言,可以根据具体情况理解上述术语在本发明中的具体含义。
除非另有定义,本文所使用的所有的技术和科学术语与属于本发明的技术领域的技术人员通常理解的含义相同。本文中在本发明的说明书中所使用的术语只是为了描述具体的实施例的目的,不是旨在于限制本发明。本文所使用的术语“及/或”包括一个或多个相关的所列项目的任意的和所有的组合。
参阅图1-图4,本发明公开了一种多层地垫,包括有:PVC层10、PE层 20以及热塑性TPO层30,其中,PVC即为聚氯乙烯材料,PE即为聚乙烯材料,热塑性TPO即为热塑性聚烯烃类材料,PVC层10和PE层20均为发泡层12。
PVC层10和PE层20的一面固定接合,热塑性TPO层30和PE层20的另一面固定接合,PVC层、PE层及热塑性TPO层的两端部通过高频压边以实现固定。
优选地,PVC层10和PE层20通过热塑性熔胶(hot-melt)以实现粘合固定。
优选地,热塑性TPO层30和PE层20通过热塑性熔胶以实现粘合固定。采用热塑性溶胶进行热熔粘合,可以抑制挥发性有机化合物,减少气味残留。
优选地,PVC层10自上而下依次包括一体成型的未发泡表层11、发泡层 12、粘合层13和织物层14,其中织物层14作为中间粘合媒介,使PVC层10 和PE层20之间通过热塑性溶胶进行热熔粘合。
优选地,织物层14为人造纤维或涤纶材料,具有良好的粘合性。
本发明还公开了用于制备上述多层地垫的制备工艺,至少包括以下步骤:
获取PVC层10步骤,采用一般发泡制作方式获取PVC层10;制作PVC 发泡层12的方法是为本领域技术人员所知悉的,具体不再赘述,PVC层10可以根据需要进行凹版印刷、热转印、喷印、压花定形等工序以得到表面图案;
获取PE层20步骤,采用一般发泡制作方式获取PE层20;制作PE发泡层 12的方法也同样为本领域技术人员所知悉,具体不再赘述;
获取热塑性TPO层30步骤,获取用于改善电流流动性的热塑性TPO层30;
由于PVC材料的电流流动性强,而PE材料会因电流产生的电阻热而熔断,因此在采用到高频压边技术时,无法直接将PVC和PE材料进行高频压边接合,本发明采用了电流流动性强的热塑性TPO层30作为地垫的底面层,不仅能使 PVC层10和PE层20较好地完成高频压边定形,而且还改善了PE层20与地面接触不紧密的情况。
第一粘合步骤,采用热塑性熔胶将PVC层10中的织物层14一面与PE层20的一面进行粘合固定,并通过热风进行吹干,其干燥工艺简单、加工便利;
第二粘合步骤,采用热塑性熔胶将PE层20的另一面和热塑性TPO层30 进行粘合固定,并通过热风进行吹干;
高频压边步骤,对高频压边机通入工作电流,通过高频压边机对PVC层10、 PE层20和热塑性TPO层30进行一定时间的高频压边定形。在高频压边工序前, PVC层10、PE层20以及热塑性TPO层30的两端长度都是接近相同的,在高频电流通过的过程中,PE层20会因电流产生的电阻热而熔化断裂,而电流流动性强的PVC层10和PE层20则完成压边定形,因此成品地垫呈PVC层10、热塑性TPO层30的两端部长度较PE层20长,且PVC层10和热塑性层的两端部固定接合。
优选地,在第二粘合步骤和高频压边步骤之间,还包括剪裁步骤:按照规格所需要的大小,将粘合后的半成品地垫进行剪裁。
优选地,在高频压边步骤中,对高频压边机通入的工作电流强度为3A及以上,比现有的电流条件2A高出约50%左右,3A的条件下可以完成工作。
优选地,在高频压边步骤中,高频压边的定形持续时间为2分钟及以上,即可使地垫保持定形状态。
通过对上述实施例的详细阐述,可以理解,本发明所能达到的有益效果有以下方面:(1)对异性物质层(PVC、PE、热塑性TPO)进行了结合,使地垫同时具备了PVC发泡层12的外观高级、触感柔软、适于进行多种表面图案的加工制作的优点,以及PE发泡层12重量轻、弹性好、造价低的特点,同时热塑性TPO层30和PVC层10的电流性均良好,两者适于进行高频压边;(2)高频压边后,降低了地垫的边缘高度(包边厚度),使婴幼儿不容易被地垫绊倒,从而发生受伤,而且节省了现有技术中需要采用织布进行包边所耗费的材料成本,以PVC层10作为地垫外层比织布更不容易受到污染残留,热塑性TPO层 30作为地垫底层改善了PE层20与地面接触不紧密的情况;(3)本发明采用热塑性熔胶对异性物质层进行粘合,相比于现有技术中采用液体粘合剂进行涂敷,工艺简单、加工便利,减小了残留溶剂的挥发性有机化合物质(VOCs)和气味,使婴幼儿的健康能得到保障。
上述实施方式仅为本发明的优选实施方式,不能以此来限定本发明保护的范围,本领域的技术人员在本发明的基础上所做的任何非实质性的变化及替换均属于本发明所要求保护的范围。
Claims (8)
1.一种多层地垫,其特征在于,包括:PVC层、PE层以及热塑性TPO层,所述PVC层和所述PE层的一面固定接合,所述热塑性TPO层和所述PE层的另一面固定接合;PVC层、PE层及热塑性TPO层的两端部通过高频压边以实现固定;
所述PVC层自上而下依次包括一体成型的未发泡表层、发泡层、粘合层和织物层,所述PVC层通过所述织物层与所述PE层接合固定。
2.如权利要求1所述的多层地垫,其特征在于,所述PVC层与所述PE层通过热塑性熔胶以实现粘合固定。
3.如权利要求1所述的多层地垫,其特征在于,所述热塑性TPO层与所述PE层通过热塑性熔胶以实现粘合固定。
4.如权利要求1所述的多层地垫,其特征在于,所述织物层为人造纤维或涤纶。
5.一种多层地垫的制备工艺,其特征在于,至少包括以下步骤:
获取PVC层步骤:采用一般发泡制作方式获取所述PVC层;
获取PE层步骤:采用一般发泡制作方式获取所述PE层;
获取热塑性TPO层步骤:获取用于改善电流流动性的所述热塑性TPO层;
第一粘合步骤:采用热塑性熔胶使所述PVC层中的织物层和所述PE层的一面进行粘合固定,并通过热风进行吹干;
第二粘合步骤:采用热塑性熔胶使所述热塑性TPO层和所述PE层的另一面进行粘合固定,并通过热风进行吹干:
高频压边步骤:对高频压边机通入工作电流,通过高频压边机对所述PVC层、所述PE层和所述热塑性TPO层进行一定时间的高频压边定形,所述PE层会因高频电流所产生的电阻热而熔化断裂,所述PVC层和所述PE层实现压边定形。
6.如权利要求5所述的多层地垫的制备工艺,其特征在于,在所述第二粘合步骤和所述高频压边步骤之间,还包括剪裁步骤:按照规格所需要的大小,将粘合后的半成品地垫进行剪裁。
7.如权利要求5所述的多层地垫的制备工艺,其特征在于,在所述高频压边步骤中,对所述高频压边机通入的工作电流强度为3A及以上。
8.如权利要求5所述的多层地垫的制备工艺,其特征在于,在所述高频压边步骤中,高频压边的定形持续时间为2分钟及以上。
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