CN112060735A - 一种双层爬爬垫及其制备工艺 - Google Patents

一种双层爬爬垫及其制备工艺 Download PDF

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CN112060735A
CN112060735A CN202011075920.1A CN202011075920A CN112060735A CN 112060735 A CN112060735 A CN 112060735A CN 202011075920 A CN202011075920 A CN 202011075920A CN 112060735 A CN112060735 A CN 112060735A
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cushion layer
layer
lower cushion
double
mortise
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杨庆锋
张镤
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Zhejiang Runyang New Materials Technology Co ltd
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Zhejiang Runyang New Materials Technology Co ltd
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Abstract

一种双层爬爬垫，由若干数量的垫子单元（1）组成；每个所述的垫子单元均包括上垫层（2）和下垫层（3），每个所述的垫子单元（1）的上垫层（2）和下垫层（3）粘接、卡接或者一体连接；所述的下垫层（3）的至少两个侧面为拼接面（31），所述拼接面上设置有至少一个榫接结构（32）；所述的上垫层（2）与所述的下垫层（3）的材质均为发泡材料，所述上垫层（2）的材质比下垫层（3）的材质柔软。本发明柔软舒适、结构简单、可拆卸收纳，可以满足绝大多数消费者的消费需求。

Description

一种双层爬爬垫及其制备工艺
技术领域
本发明涉及一种儿童专用家具，具体涉及应用于儿童在地上爬行的一种双层爬爬垫。
技术背景
爬行对于宝宝来说具有特殊意义，在宝宝学会了翻身，学会了坐立之后，那么接下来就应该是学习爬行了。宝宝经过爬行，再学会走路，对未来的平衡感以及手眼协调能力、粗细动作发展等都颇有益处，故而一款舒适、方便、耐用的爬爬垫很有市场前景，在当下的爬爬垫市场中，爬爬垫可分为整块的和可拼接的，整块的爬爬垫搬运困难，存放会占据很大的空间，不够便利；而可拼接的爬爬垫在采用榫接的结构的情况下，选用太柔软的材质则会导致在榫接的部位不牢固。
如专利申请号为CN201821283327.4的中国专利公开了一种EPP多功能儿童环保爬爬垫，包括均有EPP材料制成的两块第一方形板块、两块第二方形板块、四块第三方形板块和四块第四方形板块，两块第一方形板块和两块第二方形板块依次横向交替排列，并且通过中间连接块可折叠地连接在一起，两块第一方形板块的纵向两侧分别通过中间连接块连接有一块第三方形板块，两块第二方形板块的纵向两侧分别通过锯齿状拼接槽拼接有一块第四方形板块，两块相邻的第三方形板块和第四方形板块通过锯齿状拼接槽拼接在一起。该爬爬垫的材质选用的是EPP发泡材料，EPP材料的强度很高、弹性很好，用EPP发泡材料做爬爬垫所存在的问题便是材质不够柔软，使用时候的触感不够舒服，尤其是对小孩而言，他们很容易摔倒，而他们的皮肤又很嫩，就可能会摔破皮；故而研发一款可柔软、舒适、可拼接的爬爬垫很有必要。
发明内容
为了解决上述的技术问题，使得爬爬垫既可以足够柔软又能够拼接，本发明提供了一种双层爬爬垫。
其技术方案如下：
一种双层爬爬垫，其特征在于：所述的双层爬爬垫由若干数量的垫子单元组成；每个所述的垫子单元均包括上垫层和下垫层，每个所述的垫子单元的上垫层和下垫层粘接、卡接或者一体连接，所述的上垫层与所述的下垫层的材质均为发泡材料，所述上垫层的材质比下垫层的材质柔软；所述的下垫层的至少两个侧面为拼接面，所述拼接面上设置有至少一个榫接结构，所述的榫接结构包括设置在所述拼接面第一位置处的连接榫头和设置在所述拼接面第二位置处的连接榫槽，所述的连接榫头和所述的连接榫眼在结构上对应；相邻的两个垫子单元通过设置在其中一个垫子单元上的连接榫头和设置在另一垫子单元上的连接榫眼实现榫接。
在现有的技术方案中，所述的EPP爬爬垫所具有很多的功能，在这里只讨论它连接各爬爬垫单元以及对小孩缓冲保护的功能；所述的爬爬垫单元只有一层，这一层同时需要具有这两个功能；通过在侧面设置的榫接结构连接各个爬爬垫单元，而依靠EPP材料自身的弹性来实现对小孩缓冲保护的功能，很明显这种缓冲保护的效果是不够的，所述EPP材料的强度太高，触感偏硬，对大人来说可能仅仅是触感不好，而对小孩那脆弱的皮肤而言，就不会太安全。
在本发明的上述技术方案中，通过将爬爬垫单元连接、缓冲保护的功能分离并赋予给垫子单元的不同部位；所述垫子单元的下垫层采用强度高的材料而上垫层采用质地软的材料，将两种材料通过热复合工艺粘合在一起，从而使本爬爬垫既有很好地柔软性去保护小孩，又有足够的强度去完成坐垫单元之间的拼接。
优选地，所述的上垫层的材质为EVA、EPE和IXPE中的一种；所述的下垫层的材质为EPP、XPE中的一种。
进一步优选地，所述的上垫层的材质为IXPE；所述的下垫层的材质为EPP。
优选地，所述的上垫层的上表面上设置有凸起结构。
优选地，所述的凸起结构为1~3mm*1~3mm的四棱锥状突起。
优选地，所述的四棱锥状突起的顶部具有下凹结构，所述的下凹结构为倒四棱锥结构。
优选地，所述的连接榫头与所述的下垫层一体式连接；所述的连接榫眼为一设置在所述的下垫层底部的榫接槽；所述的连接榫头的底面与所述的下垫层的底面共面；所述的连接榫头的厚度略小于或等于所述的连接榫眼的深度，且大于所述的下垫层厚度的1/3。
在本技术方案中，所述的连接榫头的厚度不能太薄，否则连接榫头与连接榫眼配合的时候，垫子单元间的嵌合作用不够大，拼接不够牢固。
优选地，所述的连接榫头包括与所述的下垫层连接的连接部、与所述的连接榫眼相抵接的第一抵接部以及距离所述下垫层最远且与所述的连接榫眼相抵接的第二抵接部连接部、第一抵接部和第二抵接部三者一体式连接；所述的连接榫眼包括与所述的连接榫头结构相对应的连通外界的连通部，在所述连接榫眼末端的凹陷部以及平底部。
在本技术方案中，所述的连接榫头与所述的连接榫眼相嵌合，所述的第二抵接部与所述的平底部相抵接，所述的第一抵接部与所述的凹陷部相抵接，所述的连接部与所述的连通部相配合；所述的连接榫头的宽度从远离所述的下垫层的一端到靠近所述的下垫层的一端先递增后递减最后趋于不变，所述的连接榫头上宽度有变化的部位的侧面为光滑的曲面；所述的连接榫眼的宽度从靠近所述的下垫层侧面的一端到远离所述的下垫层侧面的一端先递增后递减最后趋于不变，所述的连接榫眼上宽度变化的部位的壁面为光滑的曲面；在这里宽度有变化的地方是相对宽度不变的连接部而言，将连接榫头上宽度变化的部位的壁面设计成光滑的曲面是位了拼接与拆卸时更方便、省力。
优选地，所述的下垫层的底面存在横竖垂直相交的底槽，横向和纵向至少存在一道可以等分底面的所述底槽；在所述的底槽的相交处的中部设置有高度与所述底槽的深度相等的柱状体，所述的柱状体与所述的下垫层一体式连接。
优选地，所述的下垫层的底面设置有防滑结构，所述的防滑结构由点状突起簇组成，所述的点状突起簇每平方分米上存在9~16个，每个所述的点状突起簇的面积为1~2cm2，点状突起的的数量为30~40个/cm2。
一种双层爬爬垫的制备工艺，包括如下步骤：
（1）将聚丙烯，邻苯二甲酸二异正丙酯、环氧树脂、硫酸钡、丁酯和邻苯基苯酚混炼，再加入增韧剂、防腐剂和阻燃剂，再次混炼，经过挤出、切割得到EPP珠粒；
（2）将EPP珠粒在模具中进行发泡，得到具有锁扣结构的下垫层；
（3）将低密度聚乙烯，抗氧剂、硫代二丙酸二硬脂醇酯、抗静电剂、偶氮二甲酰胺、氧化锌和硬脂酸锌加入到混炼机中进行混炼，然后转移到造粒机中进行造粒得到IXPE颗粒；
（4）将成型后的IXPE颗粒进行发泡，得到发泡棉；在发泡棉的表面流延热塑性弹性料，同时，在流延过程中将图案转印膜挤压到热塑性表面膜上，得到复合材料；
（5）将挤压后的复合材料经加热后冷压成型，制得上垫层；
（6）将下垫层和上垫层通过热复合工艺贴合到一起制得双层爬爬垫。
综上所述，本发明的有益效果有：
1、本发明中，所述垫子单元的下垫层采用强度高的材料而上垫层采用质地软的材料，将两种材料粘合在一起，从而使本爬爬垫既有很好地柔软性去保护小孩，又有足够的强度去完成坐垫单元之间的拼接；
2、本发明选用EPP发泡材料制作所述的下垫层，EPP的比重很轻，所制成的垫子单元很轻，方便使用时的拼接；EPP还隔水隔热，在地面湿度大的时候下垫层可以阻挡地面湿气向上的扩散，在冬天地面温度很低的时候下垫层还可以阻隔热量的向下传递，为孩子创造一个美好的玩耍环境；而且EPP可100%循环使用且性能几乎毫不降低，对环境友好；
3、本发明上垫层的上表面上设置有凸起结构，所述的凸起结构为的四棱锥状突起，可以起到一定的防滑作用，选用1~3mm*1~3mm大小的是为了增大摩擦的同时避免上表层的上表面上的凸起结构间的沟壑印的太深，方便擦拭脏了的部位；
4、本发明在所述的四棱锥状突起的顶部设置有倒四棱锥状的下凹结构，可以避免所述的四棱锥状突起顶部太尖锐而划伤小孩吹弹可破的肌肤；
5、本发明设置宽度从远离所述的下垫层的一端到靠近所述的下垫层的一端先递增后递减最后趋于不变的连接榫头以及与之结构对应的连接榫眼，使得所述的连接榫头与连接榫眼嵌合的更加的牢固，具体表现为当所述的榫头有向榫眼外运动的趋势的时候，所述的连接榫眼与榫头抵接的侧壁处对所述的榫头具有抵抗其向榫眼外运动的作用；
6、本发明将所述的连接榫头的侧面设计为光滑的曲面，且连接榫头的宽度变化在1~3mm以内，使得本爬爬垫单元在拼接的时候更加的方便，即把所述的连接榫头插进所述的榫眼时更省力；
7、本发明设置了横竖垂直的底槽，使得所述的下垫层的弹性比之实心板的弹性更好，小孩在上面玩耍的时候趣味性更多；底槽能够等分下垫层底面则使得下底板在增加了自身弹性的同时确保对自身有稳定的支撑作用，即当小孩踩在上面的时候，小孩的压力能够均匀的分摊，对爬爬垫结构的影响最小，相应的爬爬垫的使用寿命更加的长。
附图说明
图1为双层爬爬垫的俯视图
图2为双层爬爬垫的正视图
图3为双层爬爬垫的底面视图
图4为a处的局部放大图
图5为b处的局部放大图
图6为c处的局部放大图
图7为d处的局部放大图
图中、1-垫子单元，2-上垫层，3-下垫层，21-四棱锥状突起，31-拼接面，32-榫接结构，33-底槽，34-防滑结构，211-倒四棱锥结构，321-连接榫头，322-连接榫槽， 3211-连接部，3212-第一抵接部，3213-第二抵接部，3221-连通部，3222-凹陷部，3223-平底部。
具体实施方式
下面结合附图对本发明的实施例作详细说明。
实施例1
一种双层爬爬垫，由若干数量的垫子单元1组成；每个所述的垫子单元均包括上垫层2和下垫层3，每个所述的垫子单元1的上垫层2和下垫层3粘接、卡接或者一体连接，所述的上垫层2与所述的下垫层3的材质均为发泡材料，所述上垫层2的材质比下垫层3的材质柔软；所述的下垫层3的至少两个侧面为拼接面31，所述拼接面上设置有至少一个榫接结构32，所述的榫接结构包括设置在所述拼接面第一位置处的连接榫头321和设置在所述拼接面第二位置处的连接榫槽322，所述的连接榫头321和所述的连接榫眼322在结构上对应；相邻的两个垫子单元1通过设置在其中一个垫子单元1上的连接榫头321和设置在另一垫子单元1上的连接榫眼322实现榫接。
所述的上垫层2的材质为IXPE；所述的下垫层3的材质为EPP，IXPE材质过于柔软做出来的爬爬垫不能采用榫接结构的拼接方式，故而只用来做上垫层2，而EPP的强度颇高，可用来做具有榫接结构32的下垫层3。
所述的上垫层2的上表面上设置有凸起结构；所述的凸起结构为3mm*3mm的四棱锥状突起21。所述的四棱锥状突起21的顶部具有下凹结构，所述的下凹结构为倒四棱锥结构211，设置所述的凸起结构作为防滑的结构，同时也考虑到孩子的安全问题，故而通过设置倒四棱锥结构211以消除四棱锥状突起21的锐利。
所述的连接榫头321与所述的下垫层3一体式连接；所述的连接榫眼322为一设置在所述的下垫层3底部的榫接槽；所述的连接榫头321的底面与所述的下垫层3的底面共面；所述的连接榫头321的厚度略小于或等于所述的连接榫眼322的深度，且均为所述的下垫层3厚度的1/2。
所述的连接榫头321包括与所述的下垫层3连接的连接部3211、与所述的连接榫眼322相抵接的第一抵接部3212以及距离所述下垫层3最远且与所述的连接榫眼322相抵接的第二抵接部3213连接部3211、第一抵接部3212和第二抵接部3213三者一体式连接；所述的连接榫眼322包括与所述的连接榫头321结构相对应的连通外界的连通部3221，在所述连接榫眼322末端的凹陷部3222以及平底部3223。
所述的下垫层3的底面存在横竖垂直相交的底槽33，横向和纵向至少存在一道可以等分底面的所述底槽33；在所述的底槽33的相交处的中部设置有高度与所述底槽33的深度相等的柱状体，所述的柱状体与所述的下垫层3一体式连接。
所述的下垫层3的底面设置有防滑结构34，所述的防滑结构34由点状突起簇组成，所述的点状突起簇每平方分米上存在16个，每个所述的点状突起簇的面积为1cm2，点状突起的的数量为40个/cm2。
双层爬爬垫的制备工艺，包括如下步骤：
（1）将以重量份数计，50份聚丙烯、30份邻苯二甲酸二异正丙酯、0.5份环氧树脂、2.1份硫酸钡、10.5份丁酯和11份邻苯基苯酚加入到混炼机中进行混炼，再加入0.7份增韧剂、1.4份防腐剂和3份阻燃剂，再次混炼得到EPP发泡母粒；
（2）将EPP发泡母粒投入压力罐内，用压缩空气进行阶段性加压至0.500Mpa，并稳压0.500Mpa 2小时，将稳压好的珠粒投入到已经预热到90℃的发泡罐内再用0.3Mpa蒸汽加热5S并稳压5S，得到EPP珠粒；最后把EPP珠粒在模具中进行发泡，得到具有锁扣结构的下垫层3；
（3）将以重量份数计，100份低密度聚乙烯，1份1010抗氧剂、0.9份硫代二丙酸二硬脂醇酯、20份抗静电剂、16份偶氮二甲酰胺、0.4份氧化锌和1份硬脂酸锌加入到混炼机中进行混炼，然后转移到造粒机中进行造粒得到IXPE颗粒；
（4）将IXPE颗粒进行发泡，得到发泡棉；在发泡棉的表面流延热塑性弹性料，同时，在流延过程中将图案转印膜挤压到热塑性表面膜上，得到复合材料；
（5）将挤压后的复合材料经加热后冷压成型，制得上垫层2；
（6）将下垫层3和上垫层2通过热复合工艺贴合到一起制得双层爬爬垫。
应当指出的是，对本领域的普通技术人员来说，在不脱离本发明构思的前提下，还可以做出若干变型和改进，这些都属于本发明保护范围。

Claims (10)

1.一种双层爬爬垫，其特征在于：所述的双层爬爬垫由若干数量的垫子单元（1）组成；每个所述的垫子单元均包括上垫层（2）和下垫层（3），每个所述的垫子单元（1）的上垫层（2）和下垫层（3）粘接、卡接或者一体连接，所述的上垫层（2）与所述的下垫层（3）的材质均为发泡材料，所述上垫层（2）的材质比下垫层（3）的材质柔软；所述的下垫层（3）的至少两个侧面为拼接面（31），所述拼接面上设置有至少一个榫接结构（32），所述的榫接结构包括设置在所述拼接面第一位置处的连接榫头（321）和设置在所述拼接面第二位置处的连接榫槽（322），所述的连接榫头（321）和所述的连接榫眼（322）在结构上对应；相邻的两个垫子单元（1）通过设置在其中一个垫子单元（1）上的连接榫头（321）和设置在另一垫子单元（1）上的连接榫眼（322）实现榫接。
2.根据权利要求1所述的一种双层爬爬垫，其特征在于：所述的上垫层（2）的材质为EVA、EPE和IXPE中的一种；所述的下垫层（3）的材质为EPP、XPE中的一种。
3.根据权利要求1所述的一种双层爬爬垫，其特征在于：所述的上垫层（2）的上表面上设置有凸起结构。
4.根据权利要求3所述的一种双层爬爬垫，其特征在于：所述的凸起结构为1~3mm*1~3mm的四棱锥状突起（21）。
5.根据权利要求4所述的一种双层爬爬垫，其特征在于：所述的四棱锥状突起（21）的顶部具有下凹结构，所述的下凹结构为倒四棱锥结构（211）。
6.根据权利要求1所述的一种双层爬爬垫，其特征在于：所述的连接榫头（321）与所述的下垫层（3）一体式连接；所述的连接榫眼（322）为一设置在所述的下垫层（3）底部的榫接槽；所述的连接榫头（321）的底面与所述的下垫层（3）的底面共面；所述的连接榫头（321）的厚度略小于或等于所述的连接榫眼（322）的深度，且大于所述的下垫层（3）厚度的1/3。
7.根据权利要求6所述的一种双层爬爬垫，其特征在于：所述的连接榫头（321）包括与所述的下垫层（3）连接的连接部（3211）、与所述的连接榫眼（322）相抵接的第一抵接部（3212）以及距离所述下垫层（3）最远且与所述的连接榫眼（322）相抵接的第二抵接部（3213），连接部（3211）、第一抵接部（3212）和第二抵接部（3213）三者一体式连接；所述的连接榫眼（322）包括与所述的连接榫头（321）结构相对应的连通外界的连通部（3221），在所述连接榫眼（322）末端的凹陷部（3222）以及靠近所述下垫层（3）中部的平底部（3223）。
8.根据权利要求1所述的一种双层爬爬垫，其特征在于：所述的下垫层（3）的底面存在横竖垂直相交的底槽（33），横向和纵向至少存在一道可以等分底面的所述底槽（33）；在所述的底槽（33）的相交处的中部设置有高度与所述底槽（33）的深度相等的柱状体，所述的柱状体与所述的下垫层（3）一体式连接。
9.根据权利要求1所述的一种双层爬爬垫，其特征在于：所述的下垫层（3）的底面设置有防滑结构（34），所述的防滑结构（34）由点状突起簇组成，所述的点状突起簇每平方分米上存在9~16个，每个所述的点状突起簇的面积为1~2cm2，点状突起的的数量为25~30个/cm2。
10.一种双层爬爬垫的制备工艺，其特征在于：包括如下步骤：
（1）将聚丙烯，邻苯二甲酸二异正丙酯、环氧树脂、硫酸钡、丁酯和邻苯基苯酚混炼，再加入增韧剂、防腐剂和阻燃剂，再次混炼，经过挤出、切割得到EPP珠粒；
（2）将EPP珠粒在模具中进行发泡，得到具有锁扣结构的下垫层（3）；
（3）将低密度聚乙烯，抗氧剂、硫代二丙酸二硬脂醇酯、抗静电剂、偶氮二甲酰胺、氧化锌和硬脂酸锌加入到混炼机中进行混炼，然后转移到造粒机中进行造粒得到IXPE颗粒；
（4）将成型后的IXPE颗粒进行发泡，得到发泡棉；在发泡棉的表面流延热塑性弹性料，同时，在流延过程中将图案转印膜挤压到热塑性表面膜上，得到复合材料；
（5）将挤压后的复合材料经加热后冷压成型，制得上垫层（2）；
（6）将下垫层（3）和上垫层（2）通过热复合工艺贴合到一起制得双层爬爬垫。
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