CN112622138B - 一种聚乙烯瑜伽柱一次模压成型工艺 - Google Patents

一种聚乙烯瑜伽柱一次模压成型工艺 Download PDF

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CN112622138B
CN112622138B CN202011456356.8A CN202011456356A CN112622138B CN 112622138 B CN112622138 B CN 112622138B CN 202011456356 A CN202011456356 A CN 202011456356A CN 112622138 B CN112622138 B CN 112622138B
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CN112622138A (zh
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吴大胜
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Yiwu Dasheng Rubber And Plastic Products Co ltd
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Abstract

本发明公开了一种聚乙烯瑜伽柱一次模压成型工艺，包括配料、密炼、挤出、一次发泡模压成型、二次发泡定型、成型加工、检验、成品包装步骤；所述一次发泡模压成型步骤采用由上模和下模组成的一次发泡圆柱形模具，一次发泡模压成型时间55‑65min，压力15‑20Mpa，温度125‑135℃；所述二次发泡定型步骤采用一体式的二次发泡圆柱形模具，二次发泡定型时间40‑50min，温度125‑135℃。本发明大大缩短生产步骤，提高生产效率，并避免使用胶水，安全环保。

Description

一种聚乙烯瑜伽柱一次模压成型工艺
技术领域
本发明涉及瑜伽柱生产技术领域，特别涉及一种聚乙烯瑜伽柱一次模压成型工艺。
背景技术
瑜伽柱具有重量轻、富有缓冲弹性的特点；瑜伽柱可以帮助瑜伽练习者完成各项平衡动作；可消除肌肉紧张加强核心肌肉力量，灵活性以达到锻炼身体的平衡性，是现代瑜伽练习中不可或缺的器材。
随着人们生活水平的提高，对于健康的要求也越来越高，瑜伽作为一种方便、占地少的健身方式，已不仅仅是在女性之中流行，逐渐被所有人所接受，因此作为瑜伽的辅助工具，瑜伽柱的需求量自然也随之上升。现有瑜伽柱的生产工艺步骤为配料、密炼、挤出、一次发泡（平板）、二次发泡（平板）、剖切、裁条、粘合、异型模切、成型加工及检验。现有生产工艺，瑜伽柱无法一次模压成型，是先形成平板，然后再切割后用胶水粘合切成圆柱形，加工步骤复杂，生产效率低，且加工需要用到胶水，不够环保。如何提高生产效率，并使得产品更环保安全成为亟需解决的问题。
发明内容
本发明的目的在于提供一种聚乙烯瑜伽柱一次模压成型工艺，瑜伽柱一次模压成型，大大缩短生产步骤，提高生产效率，并避免使用胶水，安全环保。
本发明解决其技术问题所采用的技术方案是：
一种聚乙烯瑜伽柱一次模压成型工艺，包括配料、密炼、挤出、一次发泡模压成型、二次发泡定型、成型加工、检验、成品包装步骤；
所述一次发泡模压成型步骤采用由上模和下模组成的一次发泡圆柱形模具，一次发泡模压成型时间55-65min，压力15-20Mpa，温度125-135℃；
所述二次发泡定型步骤采用一体式的二次发泡圆柱形模具，二次发泡定型时间40-50min，温度125-135℃。
针对现有先形成平板，然后再切割后用胶水粘合切成圆柱形的工艺，为了降低生产成本，进一步提高产品安全性，本发明进行工艺革新，改变原来的分步加工方式，改为一次模压成型加工，改为一次模压成型工艺后存在以下几个技术问题：
1、原工艺采用平板发泡，对于发泡料的要求低，而采用圆柱形模具，对于发泡料的要求会有明显改变，尤其是发泡料的流动性，因模具形状改变，在模压发泡的条件下，必须解决生产配方的流动性。经过几百次的反复试验，筛选原辅材料最终完成技术配方的设计与论证。因此，针对一次模压成型工艺本发明首先对发泡料的配方进行了调整，以符合新工艺的要求。
2、由于本发明生产的为较长的圆柱形瑜伽柱，使用常规的圆柱形模具，则出现了大量的表面不良的质量问题，本发明经过探索改进，将一次发泡圆柱形模具制成中间大两端小的变形圆柱状，这样在发泡过程中就能提供一个排气通道，从而有效减少表面不良缺陷，此外，本发明还在一次发泡圆柱形模具的内表面腐蚀形成非常浅的不规则花纹，同样也提供发泡过程发泡料膨胀挤压时可以利用的排气辅助通道，从而有效减少表面不良缺陷。
3、针对产品出现的凹陷缺陷，本发明通过对二次发泡圆柱形模具进行改进，通过在二次发泡圆柱形模具表面开设排气孔，从而克服凹陷缺陷。
4、针对产品收缩缺陷，本发明对发泡料的配方进行调整，尤其是交联剂的用量，从而克服收缩缺陷。
5、针对产品偏扁的缺陷，本发明通过探索，调整了一次发泡模压成型的工艺参数，从而克服了产品偏扁的缺陷。
与现有工艺相比，本发明一次模压成型，大大节省了操作步骤，且产品生产过程无需裁切和粘合，避免使用胶水，提高了环保性。
成型加工步骤就是对二次发泡定型后的产品进行常规的表面整形和印花。
作为优选，所述配料按重量份计配方为：聚乙烯4.5-7.5份；碳酸钙1.5-3.5份；发泡剂AC：0.8-1.8份；交联剂DCP 0.04-0.1份；氧化锌0.03-0.1份；氯化石蜡0.02-0.08份；抗收缩剂0.03-0.08份。
作为优选，所述碳酸钙的细度为1000-1300目。
作为优选，所述密炼在密炼机中进行，密炼时间135-145 min，密炼温度125-130℃，密炼压力0.6-0.8Mpa。
作为优选，所述挤出在双螺杆挤出机中进行，挤出温度90-100℃。
作为优选，所述一次发泡圆柱形模具的中间大两端小，由中间向两端均匀过渡，一次发泡圆柱形模具中间的直径和两端的直径的差值在2-4mm；一次发泡圆柱形模具的直径范围在5-6cm。一次发泡圆柱形模具的长度为1.5-2.5米。本发明一次发泡圆柱形模具这样设置能有效减少表面不良缺陷。
作为优选，所述一次发泡圆柱形模具的内表面腐蚀形成不规则花纹，并在腐蚀后的内表面电镀铁氟龙涂层。电镀铁氟龙涂层是为了使得表面更光滑且更容易脱模。
作为优选，不规则花纹深度为0.15-0.25mm，铁氟龙涂层厚度为5-20微米。
作为优选，一次发泡模压成型采用平板式硫化机，平板式硫化机层数为4-5层，层距为24-30cm。为了使得原有的机器能够适用新的工艺，本发明将原有的平板式硫化机6层结构减少1-2层，并增加层距，这样不但方便了新工艺的操作要求，且使得装置能达到新工艺的压力要求。
作为优选，所述二次发泡圆柱形模具的直径为15-20cm；二次发泡圆柱形模具上均布有排气孔。
本发明的有益效果是：能大大缩短生产步骤，提高生产效率，并避免使用胶水，安全环保。
附图说明
图1是本发明的工艺流程图。
图2是现有技术剖切、裁条、粘合、异型模切四步的示意图。
图3是本发明一次发泡圆柱形模具的一种俯视图。
图4是本发明一次发泡圆柱形模具的一种侧视图。
图5是改进前和改进后产品的对比图。
具体实施方式
下面通过具体实施例，对本发明的技术方案作进一步的具体说明。
本发明中，若非特指，所采用的原料和设备等均可从市场购得或是本领域常用的。下述实施例中的方法，如无特别说明，均为本领域的常规方法。
本发明实施例一次发泡模压成型采用的设备为1350T平板硫化机，由六层改造成五层，使硫化机反压压力（≤21T）达到设计要求，层距由18cm增高为24cm，方便操作。
实施例1：
一种聚乙烯瑜伽柱一次模压成型工艺（如图1所示），包括配料、密炼、挤出、一次发泡模压成型、二次发泡定型、成型加工、检验、成品包装步骤。
所述配料按重量份计配方为：聚乙烯4.5份；1000目的碳酸钙1.5份；发泡剂AC（市售）：0.8份；交联剂DCP （市售）0.04份；氧化锌0.03份；氯化石蜡0.02份； 抗收缩剂（市售）0.03份。
所述密炼在密炼机中进行，密炼时间135 min，密炼温度130℃，密炼压力0.6Mpa。
所述挤出在双螺杆挤出机中进行，挤出温度90℃。
所述一次发泡模压成型步骤在平板硫化机中进行，采用由上模12和下模11组成的一次发泡圆柱形模具1（图3和图4），一次发泡圆柱形模具上有多根并列排布的发泡柱13，一次发泡模压成型时间55min，压力20Mpa，温度125℃；一次发泡圆柱形模具的中间大两端小，由中间向两端均匀过渡，一次发泡圆柱形模具中间的直径为52mm和两端的直径在50mm。所述一次发泡圆柱形模具的内表面腐蚀形成不规则花纹（采用现有方法），并在腐蚀后的内表面电镀铁氟龙涂层。不规则花纹深度为0.15mm，铁氟龙涂层厚度为5微米。
所述二次发泡定型步骤在烘箱中进行，采用一体式的二次发泡圆柱形模具，二次发泡圆柱形模具的直径为15cm；二次发泡圆柱形模具表面均布有排气孔；二次发泡定型时间40min，温度135℃。二次发泡定型完成后冷却。
实施例2：
一种聚乙烯瑜伽柱一次模压成型工艺（如图1所示），包括配料、密炼、挤出、一次发泡模压成型、二次发泡定型、成型加工、检验、成品包装步骤。
所述配料按重量份计配方为：聚乙烯7.5份； 1300目的碳酸钙3.5份；发泡剂AC（市售）： 1.8份；交联剂DCP （市售）0.1份；氧化锌0.1份；氯化石蜡0.08份； 抗收缩剂（市售）0.08份。
所述密炼在密炼机中进行，密炼时间145 min，密炼温度125℃，密炼压力0.8Mpa。
所述挤出在双螺杆挤出机中进行，挤出温度100℃。
所述一次发泡模压成型步骤在平板硫化机中进行，采用由上模12和下模11组成的一次发泡圆柱形模具1（图3和图4），一次发泡圆柱形模具上有多根并列排布的发泡柱13，一次发泡模压成型时间65min，压力15Mpa，温度135℃；一次发泡圆柱形模具的中间大两端小，由中间向两端均匀过渡，一次发泡圆柱形模具中间的直径为60mm和两端的直径在57mm。所述一次发泡圆柱形模具的内表面腐蚀形成不规则花纹（采用现有方法），并在腐蚀后的内表面电镀铁氟龙涂层。不规则花纹深度为0.25mm，铁氟龙涂层厚度为20微米。
所述二次发泡定型步骤在烘箱中进行，采用一体式的二次发泡圆柱形模具，二次发泡圆柱形模具的直径为20cm；二次发泡圆柱形模具表面均布有排气孔；二次发泡定型时间50min，温度125℃。二次发泡定型完成后冷却。
实施例3：
一种聚乙烯瑜伽柱一次模压成型工艺（如图1所示），包括配料、密炼、挤出、一次发泡模压成型、二次发泡定型、成型加工、检验、成品包装步骤。
所述配料按重量份计配方为：聚乙烯5.5份；1200目的碳酸钙2.5份；发泡剂AC（市售）：1.2份；交联剂DCP （市售）0.06份；氧化锌0.07份；氯化石蜡0.05份； 抗收缩剂（市售）0.05份。
所述密炼在密炼机中进行，密炼时间140 min，密炼温度128℃，密炼压力0.7Mpa。
所述挤出在双螺杆挤出机中进行，挤出温度95℃。
所述一次发泡模压成型步骤在平板硫化机中进行，采用由上模12和下模11组成的一次发泡圆柱形模具1（图3和图4），一次发泡圆柱形模具上有多根并列排布的发泡柱13，一次发泡模压成型时间60min，压力17Mpa，温度130℃；一次发泡圆柱形模具的中间大两端小，由中间向两端均匀过渡，一次发泡圆柱形模具中间的直径为55mm和两端的直径在52mm。所述一次发泡圆柱形模具的内表面腐蚀形成不规则花纹（采用现有方法），并在腐蚀后的内表面电镀铁氟龙涂层。不规则花纹深度为0.2mm，铁氟龙涂层厚度为10微米。
所述二次发泡定型步骤在烘箱中进行，采用一体式的二次发泡圆柱形模具，二次发泡圆柱形模具的直径为18cm；二次发泡圆柱形模具表面均布有排气孔；二次发泡定型时间45min，温度130℃。二次发泡定型完成后冷却。
现有工艺发泡完成后，需要剖切、裁条、粘合、异型模切四步加工成型（图2），而本发明则完全省略了这四步，大大提高生产效率，同时经过本发明的改进后，明显克服了发泡产品的缺陷（图5），其中克服表面不良问题通过对一次发泡圆柱形模具的结构及表面处理调整实现，克服凹陷问题通过在二次发泡圆柱形模具表面开设排气孔实现，克服产品收缩缺陷通过调整配方，主要是交联剂实现，克服产品偏扁缺陷通过调整一次发泡模压成型的工艺参数实现。
以上所述的实施例只是本发明的一种较佳的方案，并非对本发明作任何形式上的限制，在不超出权利要求所记载的技术方案的前提下还有其它的变体及改型。

Claims (4)

1.一种聚乙烯瑜伽柱一次模压成型工艺，其特征在于，包括配料、密炼、挤出、一次发泡模压成型、二次发泡定型、成型加工、检验、成品包装步骤；
所述一次发泡模压成型步骤采用由上模和下模组成的一次发泡圆柱形模具，一次发泡模压成型时间55-65min，压力15-20Mpa，温度125-135℃；
所述二次发泡定型步骤采用一体式的二次发泡圆柱形模具，二次发泡定型时间40-50min，温度125-135℃；
所述配料按重量份计配方为：聚乙烯4.5-7.5份；碳酸钙1.5-3.5份；发泡剂AC：0.8-1.8份；交联剂DCP 0.04-0.1份；氧化锌0.03-0.1份；氯化石蜡0.02-0.08份； 抗收缩剂0.03-0.08份；
所述一次发泡圆柱形模具的中间大两端小，由中间向两端均匀过渡，一次发泡圆柱形模具中间的直径和两端的直径的差值在2-4mm；一次发泡圆柱形模具的直径范围在5-6cm；一次发泡圆柱形模具的长度为1.5-2.5米；
所述一次发泡圆柱形模具的内表面腐蚀形成不规则花纹，并在腐蚀后的内表面电镀铁氟龙涂层；一次发泡模压成型采用平板式硫化机，平板式硫化机层数为4-5层，层距为24-30cm；
不规则花纹深度为0.15-0.25mm，铁氟龙涂层厚度为5-20微米；
所述二次发泡圆柱形模具的直径为15-20cm；二次发泡圆柱形模具上均布有排气孔。
2.根据权利要求1所述的一种聚乙烯瑜伽柱一次模压成型工艺，其特征在于，所述碳酸钙的细度为1000-1300目。
3.根据权利要求1所述的一种聚乙烯瑜伽柱一次模压成型工艺，其特征在于，所述密炼在密炼机中进行，密炼时间135-145 min，密炼温度125-130℃，密炼压力0.6-0.8Mpa。
4.根据权利要求1所述的一种聚乙烯瑜伽柱一次模压成型工艺，其特征在于，所述挤出在双螺杆挤出机中进行，挤出温度90-100℃。
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