CN112172219B - 一种双硬度模压发泡鞋底的制备方法 - Google Patents
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Abstract
本发明公开了一种双硬度模压发泡鞋底的制备方法,包括以下步骤:制备料米A;制备料米B;将料米B倒入吸料桶,经一次射出机台射出,得到冷胚;将冷胚放在真空小发泡模具的边沿,再将料米A倒入真空小发泡模具中间,合模、升温发泡,发泡结束,自动开模,得到发泡初胚;将发泡初胚放入油压模具,合模,推入二次发泡成型机的加热站位,加压、升温;然后将油压模具转移至冷却站位,加压、淋水冷却模具,拉出模具,取出成品,即得到双硬度模压发泡鞋底;本发明发泡鞋底的制备方法制备出的发泡鞋底,周围一圈的硬度为55C‑62C,中间的硬度35C‑43C,中间硬度低,有利于提高鞋底舒适性,减震性能好,周围一圈的硬度高,有利于改善软料容易塌陷的缺点。
Description
技术领域
本发明涉及发泡材料技术领域,尤其涉及一种双硬度模压发泡鞋底的制备方法。
背景技术
EVA发泡材料具有更佳的动态粘弹性质,更符合人体工学的测试要求,具有更佳的软硬度范围、柔软触感及更低的抗压缩性等,经常被各大体育品牌用于运动鞋底。同时由于其物理性能极佳,边料可回收利用,极具环保竞争力,因此逐渐取代NBR、SBR、CR等传统发泡材料,发展前景乐观。
现有的双色双硬度鞋底的成型工艺,注塑机拥有两支注射枪管,同时往注塑模具的上模和下模进行注塑,模具温度168℃-185℃,经过隔板预压后,隔板温度80℃-110℃,开模,将上模和下模分离,抽离隔板;将上模和下模再进行合模,上、下层复合材料在合模腔内进粘合、交联发泡成型,开模,即可得到双色双硬度的鞋底。料在模具中成熔融状态,在软硬临接部位,根本无法准确地定位在同一位置,导致鞋底外形产生串色、扭曲等问题。
亦或采用以EVA为主要成分的适量材料,制作未交联、发泡的第一胚片和第二胚片,然后放入模具,形成鞋底成型前的形状,再加温加压,发泡成型。在实际操作过程中,需要精确控制胚片的厚度和重量,容易导致串色和毛边问题。以上两种公开技术用于生产低结晶率材料的发泡材料,都存在材料粘度大导致注塑困难、产品尺寸稳定性差的缺点。
为了改善产品尺寸稳定性差的问题,通常考虑二次模压生产工艺,两种不同的原材料分别经密炼、开炼、挤出造粒、发泡后,均需经过冷却工序,冷却一般需要24小时,冷却后发泡初胚收缩定型,发泡初胚表面结晶,形成致密表层,然后需打粗去除表皮,再放入油压模具,加压加温,再用水冷却模具,生产工艺耗时长、生产效率低。
发明内容
本申请实施例通过提供一种双硬度模压发泡鞋底的制备方法,解决了现有技术中产品尺寸稳定性差、鞋底发泡需经冷却24小时、打粗等工序生产时间长等问题,实现了提高生产效率,节约生产成本的有益效果,特别适用于生产具有高弹、低硬度、亲肤、舒适等特性的发泡材料。
本申请实施例提供了一种双硬度模压发泡鞋底的制备方法,包括以下步骤:
步骤1:制备料米A;
步骤2:制备料米B;
步骤3:将料米B倒入吸料桶,经一次射出机台射出,模具温度5℃-20℃,得到冷胚,所述冷胚的厚度是1-7mm;
步骤4:将冷胚放在真空小发泡模具的边沿,再将料米A倒入真空小发泡模具中间,合模、升温发泡,发泡温度172℃-182℃,发泡结束,自动开模,得到温度不低于130℃的发泡初胚;
步骤5:将温度不低于130℃的发泡初胚放入油压模具,合模,推入二次发泡成型机的加热站位,加压、升温,温度170℃-180℃,时间20秒-100秒;然后将油压模具转移至冷却站位,加压、淋水冷却模具,定型时间150秒-400秒,拉出模具,取出成品,即得到双硬度模压发泡鞋底。
进一步地,所述料米A的具体制备方法为:先将原材料A混合进行密炼,调整密炼温度为95℃-98℃,保持4min-6min,然后翻料2次,继续密炼升温,出料温度为105℃-107℃,密炼结束后进行开炼、挤出造粒,得到料米A;
所述料米B的具体制备方法为:先将原材料B混合进行密炼,调整密炼温度为95℃-98℃,保持4min-6min,然后翻料2次,继续密炼升温,出料温度为105℃-107℃,密炼结束后进行开炼、挤出造粒,得到料米B。
进一步地,所述步骤5的具体步骤为:
将温度不低于130℃的发泡初胚放入油压模具,合模,推入二次发泡成型机的加热站位,加压、升温,温度170℃-180℃,时间40秒-70秒;然后将油压模具转移至冷却站位,加压、淋水冷却模具,淋水冷却模具的水温不高于5℃,定型时间220秒-300秒,拉出模具,取出成品,即得到双硬度模压发泡材料。
进一步地,所述双硬度模压发泡鞋底的边沿位置硬度比中间位置硬度大。
进一步地,所述原材料A与所述原材料B所含成分不同。
进一步地,所述原材料A中所含各原料的重量份如下:
进一步地,所述原材料B中所含各原料的重量份如下:
进一步地,所述原材料A中所含各原料的重量份如下:
进一步地,所述再生EVA的制备方法为:将生产EVA鞋底过程中产生的料头、次品、废品、边角料、废弃光伏电池封装EVA胶膜放入破碎机破碎,再经密炼制备而成;
所述增塑软木粉是将软木粉与甘油、甲酰胺复合而成的增塑软木粉。
进一步地,所述改性淀粉制备方法包括以下步骤:
1)将玉米淀粉称重置于反应釜中,在搅拌条件下,加入蒸馏水,配制成质量比为40%淀粉乳,加入占淀粉的质量分数为3%固体氯化钠,升温到50℃,以0.5mol/L的NaOH溶液调节至pH值11.0,加入占淀粉的质量分数为2%的六偏磷酸钠固体,反应过程保持pH不变,反应时间4h;
2)以0.5mol/L的HCl溶液调节至pH值为8.5,逐滴加入占淀粉质量分数为7.5%的乙酸酐,滴加过程中,不断以0.5mol/L NaOH溶液中和反应体系,使体系保持pH值不变,滴加乙酸酐结束后继续反应3.0h;
3)反应结束后,以0.5mol/L HCl溶液调节pH至中性,抽滤,用蒸馏水洗涤3次,烘干、粉碎,得乙酰化淀粉成品;
4)称取500g的乙酰化淀粉成品,控制水分在8%以下,放置在容器中,加入由甘油和甲酰胺组成的复合增塑剂,粗略搅拌后转入高速搅拌搅机中搅拌均匀,装入密闭容器中放置24h后,得改性淀粉成品。
本申请实施例中提供的一个或多个技术方案,至少具有如下技术效果或优点:
1、本申请将冷胚与料米A一并放入真空小发泡模具中,使得两者在真空小发泡模具内粘合,无需借助其他粘合剂,不会产生脱胶现象,提高产品的寿命;同时在得到发泡初胚后,立即转移至油压模具,油压升温时间大大缩短,减少能源消耗,且表面未结晶,压花纹较容易,生产时间短,无需经过冷却、打粗、品检、入库等工序,缩短生产周期40%以上,降低人工成本约30%。
2、本申请将由料米B制得的冷胚放入真空小发泡模具的边沿,相当于是建了围墙,该围墙硬度为55C-62C,然后在将料米A倒入真空小发泡模具中间,再经一系列工序后得到发泡初胚,该发泡初胚中位于真空小发泡模具中间的料米A的硬度在35C-43C,也就是发泡初胚中间(即本体)的硬度小于围墙的硬度。有利于提高鞋底舒适性,回弹率高,减震性能好;周围一圈(即边墙)的硬度高,有利于改善软料容易塌陷、压缩变性率大、起皱厉害的缺陷。
具体实施方式
为了更好的理解上述技术方案,下面将结合说明书以及具体的实施方式对上述技术方案进行详细的说明。
实施例1:
一种双硬度模压发泡鞋底的制备方法,包括以下步骤:
a)制备改性淀粉:
1)将1000g玉米淀粉置于四口反应釜中,在搅拌条件下,加入蒸馏水配制成40%(质量比)淀粉乳,加入30g固体氯化钠,升温到50℃,以0.5mol/L的NaOH溶液调节至pH值11.0,加入20g的六偏磷酸钠固体,反应过程保持pH不变,反应时间4h;
2)以0.5mol/L HCl溶液调节pH值到8.5,逐滴加入75g的乙酸酐,滴加过程中,不断以0.5mol/L NaOH溶液中和反应体系,使体系保持pH值基本不变,滴加乙酸酐结束后继续反应3.0h;
3)反应结束后,以0.5mol/L HCl溶液调节pH至中性,抽滤,用蒸馏水洗涤3次,烘干、粉碎,得乙酰化淀粉成品;
4)称取500g的乙酰化淀粉,控制水分在8%以下,至于在容器中,加入由40g甘油和15g甲酰胺组成的复合增塑剂,粗略搅拌后转入高速搅拌搅机中搅拌均匀,装入密闭容器中放置24h后,得改性淀粉成品。
b)制备再生EVA:
将生产EVA鞋底过程中产生的料头、次品、废品、边角料、废弃光伏电池封装EVA胶膜放入破碎机破碎、再经密炼制备而成。
c)制备增塑软木粉:
称取500g的软木粉,控制水分在5%以下(淀粉是多羟基化合物,很容易吸水,不是真空干燥环境,会吸收空气中的水分,因此要控制其水分),至于容器中,加入由50g甘油和25g甲酰胺组成的复合增塑剂,粗略搅拌后转入高速搅拌搅机中搅拌均匀,装入密闭容器中放置24h后,得改增塑软木粉成品。
d)制备料米A
先将EVA 7470M 25份、再生EVA 27份、增塑软木粉18份、改性淀粉20份、发泡剂AC2.5份、交联剂BIBP1.5份、硬脂酸锌1.5份、氧化锌1.0份、硬脂酸1.3份、滑石粉7份混合进行密炼,调整密炼温度为96℃,保持6min,然后翻料2次,继续密炼升温,出料温度为106℃,密炼结束后进行开炼、挤出造粒,得到料米A;
e)制备料米B
先将EVA 7350M 17份、EVA V4110J 8份、再生EVA 27份、增塑软木粉18份、发泡剂AC 2.0份、交联剂BIBP1.2份、硬脂酸锌1.5份、氧化锌1.0份、硬脂酸1.3份、滑石粉12份混合进行密炼,调整密炼温度为96℃,保持6min,然后翻料2次,继续密炼升温,出料温度为107℃,密炼结束后进行开炼、挤出造粒,得到料米B;
f)制备冷胚
将料米B倒入吸料桶,经一次射出机台射出,模具温度15℃,得到冷胚,冷胚厚度3mm;
g)发泡
将冷胚放在真空小发泡模具的边沿,再将料米A倒入真空小发泡模具中间,合模、升温发泡,发泡温度180℃,发泡结束,自动开模,得到温度不低于130130℃的发泡初胚;
h)二次发泡定型
将温度不低于130℃的发泡初胚放入油压模具,合模,推入二次发泡成型机的加热站位,加压、升温,温度180℃,时间50秒;然后将油压模具转移至冷却站位,加压、淋水冷却模具,淋水冷却模具的水温不高于5℃,定型时间280秒,拉出模具,取出成品,即得到双硬度模压发泡材料。
实施例2:
一种双硬度模压发泡鞋底的制备,包括以下步骤:
制备方法与实施例1相同,所不同的是
d)制备料米A
先将EVA 7470M 10份、EVA 7350M 10份、再生EVA 30份、增塑软木粉25份、改性淀粉15份、发泡剂AC 2.6份、交联剂BIBP1.6份、硬脂酸锌1.6份、氧化锌1.0份、硬脂酸1.3份、滑石粉5份混合进行密炼,调整密炼温度为96℃,保持6min,然后翻料2次,继续密炼升温,出料温度为106℃,密炼结束后进行开炼、挤出造粒,得到料米A。
对比例1
一种双硬度模压发泡鞋底的制作方法,包括以下步骤:
制备方法与实施例1相同,所不同的是
h)二次发泡定型
发泡初胚室温放置24小时,然后使用皮轮打粗,将发泡初胚的表皮(表面结晶导致的致密层)去除;然后将发泡初胚放入油压模具,发泡初胚温度不低于130℃,合模,推入二次发泡成型机的加热站位,加压、升温,温度180℃,时间280秒;然后将油压模具转移至冷却站位,加压、淋水冷却模具,淋水冷却模具的水温不高于5℃,定型时间280秒,拉出模具,取出成品,即得到双硬度模压发泡材料。
将本发明实施例1-2的一种双硬度模压发泡鞋底制备方法制得的产品与对比例1所得的发泡鞋底进行材料物性试验、生产时间进行对比,其中,硬度采用GS-701N硬度计测试,回弹率测试采用GT-7042-RE型冲击弹性试验机,尺寸收缩率按照70度40分钟测试,试验对比结果如下表1所示:
以上所记载,仅为利用本创作技术内容的实施例,任何熟悉本项技艺者运用本创作所做的修饰、变化,皆属本创作主张的专利范围,而不限于实施例所揭示者。
Claims (8)
1.一种双硬度模压发泡鞋底的制备方法,其特征在于,包括以下步骤:
步骤1:制备料米A;
步骤2:制备料米B;
步骤3:将料米B倒入吸料桶,经一次射出机台射出,模具温度5℃-20℃,得到冷胚,所述冷胚的厚度是1-7mm;
步骤4:将冷胚放在真空小发泡模具的边沿,再将料米A倒入真空小发泡模具中间,合模、升温发泡,发泡温度172℃-182℃,发泡结束,自动开模,得到温度不低于130℃的发泡初胚;
步骤5:将温度不低于130℃的发泡初胚放入油压模具,合模,推入二次发泡成型机的加热站位,加压、升温,温度170℃-180℃,时间20秒-100秒;然后将油压模具转移至冷却站位,加压、淋水冷却模具,定型时间150秒-400秒,拉出模具,取出成品,即得到双硬度模压发泡鞋底;
所述双硬度模压发泡鞋底的边沿位置硬度比中间位置硬度大;
所述原材料A与所述原材料B所含成分不同。
2.根据权利要求1所述的一种双硬度模压发泡鞋底的制备方法,其特征在于:
所述料米A的具体制备方法为:先将原材料A混合进行密炼,调整密炼温度为95℃-98℃,保持4min-6min,然后翻料2次,继续密炼升温,出料温度为105℃-107℃,密炼结束后进行开炼、挤出造粒,得到料米A;
所述料米B的具体制备方法为:先将原材料B混合进行密炼,调整密炼温度为95℃-98℃,保持4min-6min,然后翻料2次,继续密炼升温,出料温度为105℃-107℃,密炼结束后进行开炼、挤出造粒,得到料米B。
3.根据权利要求1所述的一种双硬度模压发泡鞋底的制备方法,其特征在于,所述步骤5的具体步骤为:
将温度不低于130℃的发泡初胚放入油压模具,合模,推入二次发泡成型机的加热站位,加压、升温,温度170℃-180℃,时间40秒-70秒;然后将油压模具转移至冷却站位,加压、淋水冷却模具,淋水冷却模具的水温不高于5℃,定型时间220秒-300秒,拉出模具,取出成品,即得到双硬度模压发泡材料。
4.根据权利要求2所述的一种双硬度模压发泡鞋底的制备方法,其特征在于,所述原材料A中所含各原料的重量份如下:
5.根据权利要求2所述的一种双硬度模压发泡鞋底的制备方法,其特征在于,所述原材料B中所含各原料的重量份如下:
6.根据权利要求4所述的一种双硬度模压发泡鞋底的制备方法,其特征在于,所述原材料A中所含各原料的重量份如下:
7.根据权利要求4-6任一所述的一种双硬度模压发泡鞋底的制备方法,其特征在于,
所述再生EVA的制备方法为:将生产EVA鞋底过程中产生的料头、次品、废品、边角料、废弃光伏电池封装EVA胶膜放入破碎机破碎,再经密炼制备而成;
所述增塑软木粉是将软木粉与甘油、甲酰胺复合而成的增塑软木粉。
8.根据权利要求4或6任一所述的一种双硬度模压发泡鞋底的制备方法,其特征在于,所述改性淀粉制备方法包括以下步骤:
1)将玉米淀粉称重置于反应釜中,在搅拌条件下,加入蒸馏水,配制成质量比为40%淀粉乳,加入占淀粉的质量分数为3%固体氯化钠,升温到50℃,以0.5mol/L的NaOH溶液调节至pH值11.0,加入占淀粉的质量分数为2%的六偏磷酸钠固体,反应过程保持pH不变,反应时间4h;
2)以0.5mol/L的HCl溶液调节至pH值为8.5,逐滴加入占淀粉质量分数为7.5%的乙酸酐,滴加过程中,不断以0.5mol/L NaOH溶液中和反应体系,使体系保持pH值不变,滴加乙酸酐结束后继续反应3.0h;
3)反应结束后,以0.5mol/L HCl溶液调节pH至中性,抽滤,用蒸馏水洗涤3次,烘干、粉碎,得乙酰化淀粉成品;
4)称取500g的乙酰化淀粉成品,控制水分在8%以下,放置在容器中,加入由甘油和甲酰胺组成的复合增塑剂,粗略搅拌后转入高速搅拌搅机中搅拌均匀,装入密闭容器中放置24h后,得改性淀粉成品。
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