CN111775382A - 一种纯天然乳胶干式片材的加工工艺 - Google Patents
一种纯天然乳胶干式片材的加工工艺 Download PDFInfo
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Abstract
一种纯天然乳胶干式片材的加工工艺。包含以下步骤:混合、熟成、发泡、定型、硫化、烘干。本发明首次采用射频技术来定型、硫化纯天然乳胶干式片材,解决了天然乳胶干式片材易分层,结构不均匀的问题,通过分段调整射频功率及射频作用时间,制备不同高度的天然乳胶干式片材,提高乳胶制品的品质。
Description
技术领域
本发明涉及乳胶海绵技术领域,尤其涉及一种纯天然乳胶干式片材的加工工艺。
背景技术
随着胶乳海绵越来越广泛的应用,人们对海绵质量要求也越来越高。干式乳胶海绵生产过程无需通过水洗,产品一次成型,既节约了水资源,无需处理过多废水,同时也减少了生产成本。但是由于其生产工艺中单纯利用烘箱来加热发泡胶乳,无法使厚的干式片材内部与外部均匀受热,从而导致产品出现分层,结构粗糙。
发明内容
本发明针对以上问题,提供了一种避免产品内部分层,提高产品品质的纯天然乳胶干式片材的加工工艺。
本发明的技术方案为:包括以下步骤:
S1、配料、熟成;将原料按配方配制搅拌均匀后,搅拌0.5-1h,预硫化处理,所述原料包括以下重量份的组分:
天然乳胶:100份;
硫化剂:8-18份;
软皂:1-10份;
硅氧烷:0.1-1份;
焦磷酸钾:0.1-1份;
S2、发泡;通过发泡机进行发泡;
S3、定型、硫化、烘干工序;发泡后胶乳进入射频设备内进行定型、硫化和烘干,完成。
步骤S1中预硫化胶乳温度为20-25℃,预硫化时间为8-12h。
步骤S3中,射频设备分段调整功率及时间进行定型、硫化和烘干;
定型时,射频定型功率为30~60kW,定型时间为1~6min;
硫化时,射频硫化功率为30~70kW,硫化时间为15~25min;
烘干时,射频烘干频率为30~60kW,烘干时间为10~20min。
与现有技术相比,本发明的有益效果为:
本发明首次采用射频技术加工纯天然乳胶干式片材,解决了天然乳胶干式片材易分层,结构不均匀的问题,通过分段调整定型、硫化、烘干过程中射频功率及射频作用时间,完成天然乳胶干式片材的定型、硫化、烘干过程,便于制备不同高度的天然乳胶干式片材,产品一次成型,保证了乳胶制品的品质。
具体实施方式
下面结合具体实例对本发明作进一步解说。
本发明包括以下步骤:
S1、配料、熟成;将原料按配方配制搅拌均匀后,搅拌0.5-1h,预硫化处理,所述原料包括以下重量份的组分:
天然乳胶:100份;
硫化剂:8-18份;
软皂:1-10份;
硅氧烷:0.1-1份;
焦磷酸钾:0.1-1份;
S2、发泡;通过发泡机进行发泡;
S3、定型、硫化、烘干工序;发泡后胶乳进入射频设备内进行定型、硫化和烘干,完成。
步骤S1中预硫化胶乳温度为20-25℃,预硫化时间为8-12h。
步骤S3中,射频设备分段调整功率及时间进行定型、硫化和烘干;
定型时,射频定型功率为30~60kW,定型时间为1~6min;
硫化时,射频硫化功率为30~70kW,硫化时间为15~25min;
烘干时,射频烘干频率为30~60kW,烘干时间为10~20min。
本发明首次采用射频技术,通过分段调整定型、硫化、烘干过程中射频功率及射频作用时间,完成天然乳胶干式片材的定型、硫化、烘干过程,便于制备不同高度的天然乳胶干式片材,产品一次成型,保证了乳胶制品的品质。
步骤S1和S2之间,还包括制备紫胶树脂钙盐聚集体,并将紫胶树脂钙盐聚集体引入预硫化胶乳中进行搅拌;
其中,紫胶树脂钙盐聚集体的制备过程为:将紫胶树脂钠盐配制成6wt%的紫胶树脂钠盐溶液(即紫胶树脂钠盐溶于水中),用蒸馏水配制0.1mol/L的CaCl2溶液,20℃条件下缓慢搅拌紫胶树脂钠盐溶液,然后缓慢滴加CaCl2溶液,混合搅拌20min,室温静置6h,过滤得到析出的固体,冷冻干燥后得到紫胶树脂钙盐聚集体;
在发泡前将紫胶树脂钙盐聚集体引入预硫化胶乳中,紫胶树脂钠盐为类不对称双子(Gemini)表面活性剂结构,Ca2+诱导作用下进行聚集,形成多孔结构聚集体紫胶树脂钙盐,可以吸附、锁住乳胶制品中部分挥发性有机化合物,紫胶树脂是由紫胶桐酸与壳脑酸形成的内酯和交酯组成,紫胶桐酸为直链大分子,且为含有多羟基饱和碳链,因此,紫胶树脂钙盐表面存在大量羟基,通过氢键作用有利于有机化合物(如醇类、胺类等)的吸附。
从而,使得生产出的乳胶制品达到低气味、低VOC环保性的要求。
步骤S2和S3之间,还包括热风定型,使用二氧化碳和热空气混合的方式进行定型,实现初步定型。
发泡胶乳在热风定型前段表面已经初步的胶凝,具有一定强度,经过中段时,二氧化碳随热空气渗透进入发泡胶乳中与其中的水分结合形成碳酸,与天然乳胶中的氨形成碳酸氨,降低pH,能够使发泡胶乳加速胶凝,提前内部进行胶凝,提高生产效率。
再进入后续的射频设备进行定型、硫化和烘干,提高产品的加工质量。
实施例1
本发明包括以下步骤:
S1、配料、熟成;将原料按配方配制搅拌均匀后,搅拌0.5h,预硫化处理,预硫化胶乳温度为20℃,预硫化时间为8h。所述原料由以下重量份的组分制成:
天然乳胶:100份;
硫化剂:8份;
软皂:3份;
硅氧烷:0.5份;
焦磷酸钾:0.1份;
S2、发泡;发泡机进行发泡;
S3、定型、硫化、烘干工序。射频定型功率为30kW,定型时间为2min,射频硫化功率为60kW,硫化时间为15min,射频烘干频率为40kW,时间为10min。
实施例2
本发明包括以下步骤:
S1、配料、熟成。将原料按配方配制搅拌均匀后,搅拌0.8h,预硫化处理,预硫化胶乳温度为25℃,预硫化时间为10h。所述原料由以下重量份的组分制成:
天然乳胶:100份;
硫化剂:10份;
软皂:5份;
硅氧烷:0.5份;
焦磷酸钾:0.3份。
S2、发泡;发泡机进行发泡;
S3、定型、硫化、烘干工序。射频定型功率为40kW,定型时间为2min,射频硫化功率为60kW,硫化时间为20min,射频烘干频率为40kW,时间为15min。
实施例3
本发明包括以下步骤:
S1、配料、熟成;将原料按配方配制搅拌均匀后,搅拌1h,预硫化处理,预硫化胶乳温度为25℃,预硫化时间为12h。所述原料由以下重量份的组分制成:
天然乳胶:100份;
硫化剂:12份;
软皂:8份;
硅氧烷:0.5份;
焦磷酸钾:0.5份;
S2、发泡;发泡机进行发泡;
S3、定型、硫化、烘干工序。射频定型功率为40kW,定型时间为2min,射频硫化功率为60kW,硫化时间为25min,射频烘干频率为30kW,时间为10min。
以上所述,仅为本发明的较佳实施例而已,并非用于限定本发明的保护范围。
Claims (3)
1.一种纯天然乳胶干式片材的加工工艺,其特征在于,包括以下步骤:
S1、配料、熟成;将原料按配方配制搅拌均匀后,搅拌0.5-1h,预硫化处理,所述原料包括以下重量份的组分:
天然乳胶:100份;
硫化剂:8-18份;
软皂:1-10份;
硅氧烷:0.1-1份;
焦磷酸钾:0.1-1份;
S2、发泡;通过发泡机进行发泡;
S3、定型、硫化、烘干工序;发泡后胶乳进入射频设备内进行定型、硫化和烘干,完成。
2.根据权利要求1所述的一种纯天然乳胶干式片材的加工工艺,其特征在于,步骤S1中预硫化胶乳温度为20-25℃,预硫化时间为8-12h。
3.根据权利要求1所述的一种纯天然乳胶干式片材的加工工艺,其特征在于,步骤S3中,射频设备分段调整功率及时间进行定型、硫化和烘干;
定型时,射频定型功率为30~60kW,定型时间为1~6min;
硫化时,射频硫化功率为30~70kW,硫化时间为15~25min;
烘干时,射频烘干频率为30~60kW,烘干时间为10~20min。
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