CN114209233A - 一种马桶座圈及其制备方法 - Google Patents

一种马桶座圈及其制备方法 Download PDF

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CN114209233A
CN114209233A CN202111517248.1A CN202111517248A CN114209233A CN 114209233 A CN114209233 A CN 114209233A CN 202111517248 A CN202111517248 A CN 202111517248A CN 114209233 A CN114209233 A CN 114209233A
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popcorn
density
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CN114209233B (zh
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林孝发
林孝山
李伟宇
彭满新
梁贺
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Jomoo Kitchen and Bath Co Ltd
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Abstract

本发明公开了一种马桶座圈，包括底板、高回弹性发泡层和表面层；其中高回弹性发泡层由爆米花颗粒与胶黏剂复合形成，包括下层和上层，上层的爆米花颗粒密度小于下层；所述上层包括坐骨部位区、坐骨部位前侧和坐骨部位后侧，其中坐骨部位区的爆米花颗粒密度小于坐骨部位前侧和坐骨部位后侧。本发明还公开了其制备方法。本发明的马桶座圈可提高使用舒适度和用户体验感。

Description

一种马桶座圈及其制备方法
技术领域
本发明涉及卫浴技术领域，尤其涉及一种马桶座圈及其制备方法。
背景技术
现有的马桶座圈，质地又硬又冷，且表面触感差，很容易粘皮肤，导致用户体验感很差。
为达到柔性和温感的效果，现有制作座圈的技术方案有：一、刚性骨架层+外部包覆柔性层，二、在座圈表面设计一层弹性体材料层，三、在座圈表面设计一层弹性气垫层，等。然而，方案一的刚性骨架结构在体重比较大的人使用的时候会压在骨架上，舒适度反而不佳；方案二的弹性体材料例如软橡胶材料、医用硅胶材料等存在柔性不足、回弹性差等缺点，用久了容易变形，且容易老化，耐用性差；方案三的气垫层设计容易泄气，使用不便且存在安全隐患。上述结构设计难以实现改善用户体验感的效果。
发明内容
本发明的目的在于克服现有技术存在的不足，提供一种马桶座圈及其制备方法。
为了实现以上目的，本发明的技术方案为：
一种马桶座圈，包括底板、包覆于底板上的高回弹性发泡层和包覆于高回弹性发泡层上的表面层；所述高回弹性发泡层由爆米花颗粒与胶黏剂复合形成，包括下层和上层，其中上层的爆米花颗粒密度小于下层；所述上层包括坐骨部位区、坐骨部位前侧和坐骨部位后侧，其中坐骨部位区的爆米花颗粒密度小于坐骨部位前侧和坐骨部位后侧。
可选的，所述表面层为TPE膜、TPR膜、TPV膜、TPU膜、聚烯烃膜、PVDF膜、PVF膜、聚酰胺膜、液态硅胶膜、硅胶皮革膜或ABS膜。
可选的，所述表面层的厚度为0.03mm～0.5mm，硬度为Shore 10D～Shore 80D。
可选的，所述爆米花颗粒为E-TPU爆米花颗粒，尼龙爆米花颗粒或TPEE爆米花颗粒。
可选的，所述上层的爆米花颗粒的粒径小于所述下层。
可选的，所述坐骨部位前侧和坐骨部位后侧的至少部分区域的爆米花颗粒密度渐变。
可选的，所述坐骨部位前侧和坐骨部位后侧分别包括与所述坐骨部位区相接的过渡区和与过渡区相接的固定区；所述过渡区的爆米花颗粒密度由所述坐骨部位区一侧向所述固定区一侧渐变式增大，且爆米花颗粒密度下限与所述坐骨部位区的爆米花颗粒密度相同，爆米花颗粒密度上限与所述固定区的爆米花颗粒密度相同。
可选的，所述下层的爆米花颗粒密度为0.70g/cm3～0.90g/cm3；所述坐骨部位区的爆米花颗粒密度为0.10g/cm3～0.30g/cm3，所述固定区的爆米花颗粒密度为0.55g/cm3～0.65g/cm3。可选的，所述胶黏剂为热熔胶粉，所述爆米花颗粒与热熔胶粉的重量比为100:(3～8)。
可选的，所述胶黏剂为发泡胶黏剂，所述爆米花颗粒与发泡胶黏剂的重量比为60:40～85:15。
上述马桶座圈的制备方法，包括以下步骤：
1)制作各个区域的预成型模具；
2)使爆米花颗粒和胶黏剂在预成型模具中混合，通过热压工艺预成型成各个区域对应的形状；
3)将各个区域的预成型半成品装填到最终成型模具中，通过水蒸汽热压成型形成高回弹性发泡层；
4)使高回弹性发泡层包覆于底板的上表面及侧面上；
5)将表面层通过3DVOF工艺、灌注工艺、注塑工艺或者TOM工艺包覆在高回弹性发泡层的表面，表面层与底板在背面的接缝处采用高温焊接处理。
可选的，预成型模具有两部分组成，一部分为产品区，一部分为缓冲区；其中产品区模具的厚度比最终产品对应区域的厚度稍大一些；缓冲区为产品区底部延伸出来的一部分。
可选的，所述坐骨部位前侧和坐骨部位后侧的至少部分区域的爆米花颗粒密度渐变，所述渐变的部分区域的制备方法为：所述预成型模具的底部设有吹风口，顶部设有出风孔；步骤2)中，将不同密度的爆米花颗粒与热熔胶粉的混合物倒入预成型模具，通过吹风口向预成型模具里吹风从而使爆米花颗粒按密度由上至下变高进行渐变式堆积，然后将模具吹风口的部位朝上放置，合模通过热压工艺进行预成型。
可选的，所述坐骨部位前侧和坐骨部位后侧的至少部分区域的爆米花颗粒密度渐变，所述渐变的部分区域的制备方法为：所述预成型模具的底部设有吹风口，顶部设有出风孔；步骤2)中，将不同密度的爆米花颗粒倒入预成型模具，通过吹风口向预成型模具里吹风从而使爆米花颗粒按密度由上至下变高进行渐变式堆积，然后将模具吹风口的部位朝上放置，合模后将液态发泡胶黏剂注入预成型模具中，通过加热加压工艺进行预成型。
本发明的有益效果为：
(1)采用爆米花发泡颗粒材料，具有极佳的回弹性、颜色可调性和耐用性；同时发泡层能避免像普通PP注塑座圈那样的冰凉的坐感；
(2)采用表面层，提高亲肤性、耐污染性和耐黄变性能；
(3)高回弹性发泡层的上层采用较低密度的材料，提供柔软的坐感；下层采用较高密度的材料，能保证平均的应力分布；
(4)高回弹性发泡层根据人体工程学原理，不同部位采用不同密度的爆米花材料，其中坐骨部位区域采用密度较小的爆米花发泡材料，前后侧采用密度较大的爆米花发泡材料以提高使用舒适度，实用性强。
附图说明
图1为本发明一实施例的马桶座圈的横向截面示意图；
图2为本发明一实施例的高回弹性发泡层的俯视结构示意图；
图3为本发明一实施例的高回弹性发泡层的纵向截面示意图。
具体实施方式
以下结合附图和具体实施例对本发明做进一步解释。本发明的各附图仅为示意以更容易了解本发明，其具体比例可依照设计需求进行调整。文中所描述的图形中相对元件的上下关系以及正面/背面的定义，在本领域技术人员应能理解是指以马桶座圈的正常使用状态下的位置关系而言，因此皆可以翻转而呈现相同的构件，此皆应同属本说明书所揭露的范围。
参考图1，一实施例的马桶座圈，包括底板100、包覆于底板100上的高回弹性发泡层200和包覆于高回弹性发泡层200上的表面层300。
表面层300为亲肤耐黄耐污材料的膜层，例如TPE膜、TPR膜、TPV膜、TPU膜、聚烯烃膜、PVDF膜、PVF膜、聚酰胺膜、硅胶皮革膜、ABS膜等；优选TPV膜，TPV膜具有皮肤触感好、耐黄变、耐污染性、耐老化的优点。表面层300材质的硬度为Shore10D～Shore 80D，优选25D～45D。表面层300的厚度在0.03mm～0.5mm之间。表面层300的正表面(即使用者的接触面)优选磨砂效果，提供更加优异的触感。表面层300的颜色为白色或者灰色等颜色，优选陶瓷白色，可以和陶瓷本体形成一体。
高回弹性发泡层200材质为E-TPU爆米花颗粒加胶黏剂或者尼龙爆米花颗粒加胶黏剂或者TPEE爆米花颗粒加胶黏剂；其中E-TPU爆米花颗粒或者尼龙爆米花颗粒或者TPEE爆米花颗粒是通过超临界流体发泡法做出来的全闭孔材料，全闭孔的发泡材料能提供更加优异的回弹性，提高座圈的耐用性。胶黏剂可以是例如热熔胶粉，且爆米花颗粒与热熔胶粉的重量比为100:(3～8)。胶黏剂也可以为PU发泡胶黏剂，所述爆米花颗粒与PU发泡胶黏剂的重量比为85:15～60:40，PU发泡胶黏剂的密度可控制在0.2～0.8g/cm3之间。爆米花颗粒和胶黏剂优选均匀混合。
高回弹性发泡层200的厚度控制在2mm～80mm之间，爆米花颗粒的密度在0.10g/cm3～0.90g/cm3之间，爆米花颗粒的尺寸在2mm～12mm之间。参考图2和图3，高回弹性发泡层200包括下层210和上层220。在密度上，上层220采用较低密度的材料，提供柔软的坐感；下层210采用较高密度的材料，能保证平均的应力分布；具体，上层220的爆米花颗粒密度在0.10g/cm3～0.70g/cm3之间，下层210的爆米花颗粒密度在0.70g/cm3～0.90g/cm3之间，并且上层220的爆米花颗粒密度小于下层210。在粒径上，上层220采用粒径比较小的爆米花颗粒，达到与表面层300更好的贴合效果和更好的外观效果；下层210采用粒径比较大的爆米花颗粒，以达到更好的成本管控；具体，上层220的爆米花颗粒尺寸在2mm～7mm之间；下层210的爆米花颗粒尺寸在6mm～12mm之间，并且上层220的爆米花颗粒尺寸小于下层210。
进一步，根据人体工程学原理，上层220包括坐骨部位区221、坐骨部位前侧(包括过渡区222和固定区223)和坐骨部位后侧(包括过渡区224和固定区225)，不同区域采用不同密度的爆米花颗粒。作为常识，这里所指的坐骨部位区是指使用者如厕时，马桶座圈与使用者的坐骨部位接触的区域。坐骨部位区221采用密度较小的爆米花颗粒，坐骨部位前侧和后侧采用密度较大的爆米花颗粒。其中坐骨部位区221采用单一密度的爆米花颗粒，其密度在0.10g/cm3～0.30g/cm3之间。坐骨部位前侧和后侧均采用多种密度的爆米花颗粒，且爆米花颗粒数量在不同密度上均匀分布，即坐骨部位前侧和后侧沿着前后延伸的方向至少部分区域爆米花颗粒密度是渐变，使各个区域之间不存在密度突变。
具体，过渡区222由相接的坐骨部位区221向相接的固定区223方向、过渡区224由相接的坐骨部位区221向相接的后侧区225方向的爆米花颗粒密度分别逐渐增大，其中过渡区222、224的爆米花颗粒密度下限分别为0.10g/cm3～0.30g/cm3之间，即和坐骨部位区221的爆米花颗粒密度一致，以保证坐骨部位区221和过渡区222、224在爆米花颗粒密度上的渐变式过度；爆米花颗粒密度上限为0.55g/cm3～0.65g/cm3。固定区223和固定区225采用单一密度的爆米花颗粒，且密度与相邻过渡区222、224的爆米花颗粒密度上限一致，以保证过渡区222、224分别和固定区223、固定区225在爆米花颗粒密度上的渐变式过度。通过上述结构设计，一方面符合人体工学原理，提供一个适应人体构造的区域分布结构以得到较好的使用舒适度；另一方面确保了座圈的一体性，以得到适合的应力分布，避免局部突变产生的裂断等问题。
底板100的材质为SMC板、碳纤维板、BMC板、脲醛树脂板等热固性材料板材；也可为工程塑料板，如PBT、PA、PET、PEEK、PPS、PC、PC/ABS、POM、POK、PPO、ASA、PPSU、PSU、PES等材质；优选SMC板、碳纤维板、BMC板、脲醛树脂板，可以达到更薄更轻更强的效果，提供一个刚性支撑。常规的，底板100上分布有四个脚垫安装孔。
底板100的宽度比整体座圈的宽度略窄5mm～10mm，两侧各窄2.5mm～5.0mm；即底板100的上表面以及两个侧面均被高回弹性发泡层200包覆。表面层300通过3D VOF工艺、注塑工艺或者TOM工艺包覆在高回弹性发泡层200的表面。从而，表面层300与底板100的接缝处位于整体座圈的背面，这样可以达到更好的外观效果，并且起到防水的作用。
以下一实施例详细说明上述马桶座圈的制作工艺。
其中高回弹性发泡层200的制作工艺，是首先制作如图1～3所示各个部位的预成型模具，其中：a、预成型模具有两部分组成，一部分为产品区，一部分为缓冲区；其中产品区模具的厚度比最终产品对应区域的厚度稍大一些，约大1～5㎜；缓冲区为产品区底部延伸出来5～15cm；b、预成型模具底部有若干个可开合的吹风口，顶部也设置有尺寸远小于爆米花颗粒尺寸的出风孔，爆米花颗粒大小为5㎜以上，预成型模具顶部的出风孔尺寸在1㎜以下。
以过渡区采用密度范围为0.30-0.55g/cm3的E-TPU材质爆米花颗粒，采用TPU热熔胶粉作为胶黏剂制作为例，具体步骤为：
1、热熔胶粉和爆米花颗粒静电吸附：将热熔胶粉和密度为0.30-0.55g/cm3的爆米花颗粒放入高速搅拌机中进行高速搅拌，通过搅拌产证的静电将热熔胶粉吸附在密度为0.35-0.55g/cm3的爆米花颗粒表面；采用的爆米花颗粒的数量在0.30-0.55g/cm3密度范围上均匀分布；
2、热熔胶粉和爆米花颗粒熔融吸附：将步骤1制备的表面有物理静电吸附热熔胶粉的爆米花颗粒均匀分散平铺在特氟龙传送带上，爆米花颗粒在传送带上分散较开，基本上不会相互接触，将载有爆米花颗粒的传送带穿过加热炉，加热炉的温度在80℃～120℃之间，加热炉的温度使热熔胶粉部分熔融，实现了热熔胶粉和爆米花颗粒的熔融吸附；
3、爆米花颗粒渐变式密度堆积：将步骤2制备的表面粘附有热熔胶粉的爆米花颗粒倒入相应的预成型模具，吹风口朝上(即吹风口在底部)，然后通过吹风口向预成型模具里面吹风，这样密度较高的爆米花会聚集在底部，密度较低的爆米花颗粒聚集在上面，实现了爆米花颗粒的渐变式密度堆积；
4、中温预成型：将上模和步骤3准备的物料进行合模加压，并通过红外加热等方式，将物料加热到80℃～120℃进行预成型，使得各个爆米花颗粒表面附着的热熔胶粉软化并且将各个爆米花颗粒粘结在一起，预成型成该区域对应的形状。即得到过渡区预成型半成品。
参考上述制作方法，制作其他区域；若单一密度的区域则不需要渐变式堆积的过程；各个区域的预成型完成后，再将各个区域的预成型半成品装填到最终成型模具中，进行水蒸汽热压成型，得到高回弹性发泡层200。
高回弹发泡层200与底板100之间可两种工艺结合，一是采用胶黏剂，在底板表面刷胶后放入高回弹发泡层，然后放入模具内压合固定成型；二是采用卡扣结构，底板上设置凹槽，高回弹发泡层带有匹配的凸块结构，使凸块嵌入凹槽实现两者结合；从而使高回弹性发泡层200包覆底板100的上表面和侧面。
然后，通过3D VOF工艺、灌注工艺、注塑工艺或者TOM工艺将表面层300包覆在高回弹性发泡层200的表面，背面的接缝处需要经过高温焊接处理，经过处理后，表面层300和底板100在接缝处融为一体，整个产品的外观一致均匀，并且上表面无接缝，水分不会残留在上表面，因此不会因为水分残留而引起气泡、鼓包、剥离等缺陷。
在另一实施例中，采用PU发泡胶黏剂和E-TPU材质爆米花颗粒制作高回弹性发泡层，同样以过渡区的制作为例，将不同密度的爆米花颗粒倒入预成型模具后，通过吹风口向预成型模具里吹风从而使爆米花颗粒按密度由上至下变高进行渐变式堆积，在吹风的同时顶部的小出风孔是处于打开状态，吹风结束后，顶部的小出风口关闭；然后将模具原先吹风口的部位朝上放置，然后将合模板合上，再通过合模板上的注料孔将液态PU发泡胶黏剂注入预成型模具中；然后通过加热加压工艺进行预成型，使得胶黏剂发生部分固化发泡胶黏将各个爆米花颗粒粘结在一起，形成一个预成型的半成品。通过调整PU发泡胶黏剂的合适的添加比例，可以兼具高性能和低成本的优势。
得到的马桶座圈具有极佳的回弹性、亲肤性、耐污染性、耐黄变性能，体验感佳(无用来提高附着力的网格及用来固定的凸块，外观均一、外观面无接缝，颜值高、颜色可调性高，适于实际生产应用。
上述实施例仅用来进一步说明本发明的一种马桶座圈及其制备方法，但本发明并不局限于实施例，凡是依据本发明的技术实质对以上实施例所作的任何简单修改、等同变化与修饰，均落入本发明技术方案的保护范围内。

Claims (12)

1.一种马桶座圈，其特征在于：包括底板、包覆于底板上的高回弹性发泡层和包覆于高回弹性发泡层上的表面层；所述高回弹性发泡层由爆米花颗粒与胶黏剂复合形成，包括下层和上层，其中上层的爆米花颗粒密度小于下层；所述上层包括坐骨部位区、坐骨部位前侧和坐骨部位后侧，其中坐骨部位区的爆米花颗粒密度小于坐骨部位前侧和坐骨部位后侧。
2.根据权利要求1所述的马桶座圈，其特征在于：所述表面层为TPE膜、TPR膜、TPV膜、TPU膜、聚烯烃膜、PVDF膜、PVF膜、聚酰胺膜、液态硅胶膜、硅胶皮革膜或ABS膜。
3.根据权利要求1所述的马桶座圈，其特征在于：所述爆米花颗粒为E-TPU爆米花颗粒，尼龙爆米花颗粒或TPEE爆米花颗粒。
4.根据权利要求1所述的马桶座圈，其特征在于：所述上层的爆米花颗粒的粒径小于所述下层。
5.根据权利要求1所述的马桶座圈，其特征在于：所述坐骨部位前侧和坐骨部位后侧的至少部分区域的爆米花颗粒密度渐变。
6.根据权利要求5所述的马桶座圈，其特征在于：所述坐骨部位前侧和坐骨部位后侧分别包括与所述坐骨部位区相接的过渡区和与过渡区相接的固定区；所述过渡区的爆米花颗粒密度由所述坐骨部位区一侧向所述固定区一侧渐变式增大，且爆米花颗粒密度下限与所述坐骨部位区的爆米花颗粒密度相同，爆米花颗粒密度上限与所述固定区的爆米花颗粒密度相同。
7.根据权利要求6所述的马桶座圈，其特征在于：所述下层的爆米花颗粒密度为0.70g/cm3～0.90g/cm3；所述坐骨部位区的爆米花颗粒密度为0.10g/cm3～0.30g/cm3，所述固定区的爆米花颗粒密度为0.55g/cm3～0.65g/cm3。
8.根据权利要求1所述的马桶座圈，其特征在于：所述胶黏剂为热熔胶粉，所述爆米花颗粒与热熔胶粉的重量比为100:(3～8)。
9.根据权利要求1所述的马桶座圈，其特征在于：所述胶黏剂为发泡胶黏剂，所述爆米花颗粒与发泡胶黏剂的重量比为85:15～60:40。
10.一种权利要求1～9任一项所述的马桶座圈的制备方法，其特征在于包括以下步骤：
1)制作各个区域的预成型模具；
2)使爆米花颗粒和胶黏剂在预成型模具中混合，通过热压工艺预成型成各个区域对应的形状；
3)将各个区域的预成型半成品装填到最终成型模具中，通过水蒸汽热压成型形成高回弹性发泡层；
4)使高回弹性发泡层包覆于底板的上表面及侧面上；
5)将表面层通过3DVOF工艺、灌注工艺、注塑工艺或者TOM工艺包覆在高回弹性发泡层的表面，表面层与底板在背面的接缝处采用高温焊接处理。
11.根据权利要求10所述的制备方法，其特征在于：所述坐骨部位前侧和坐骨部位后侧的至少部分区域的爆米花颗粒密度渐变，所述渐变的部分区域的制备方法为：所述预成型模具的底部设有吹风口，顶部设有出风孔；步骤2)中，将不同密度的爆米花颗粒与热熔胶粉的混合物倒入预成型模具，通过吹风口向预成型模具里吹风从而使爆米花颗粒按密度由上至下变高进行渐变式堆积，然后将模具吹风口的部位朝上放置，合模通过热压工艺进行预成型。
12.根据权利要求10所述的制备方法，其特征在于：所述坐骨部位前侧和坐骨部位后侧的至少部分区域的爆米花颗粒密度渐变，所述渐变的部分区域的制备方法为：所述预成型模具的底部设有吹风口，顶部设有出风孔；步骤2)中，将不同密度的爆米花颗粒倒入预成型模具，通过吹风口向预成型模具里吹风从而使爆米花颗粒按密度由上至下变高进行渐变式堆积，然后将模具吹风口的部位朝上放置，合模后将液态发泡胶黏剂注入预成型模具中，通过加热加压工艺进行预成型。
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