CN114589860A - 一种聚氨酯瑜珈垫生产工艺 - Google Patents
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Abstract
本发明是一种聚氨酯瑜珈垫生产工艺,使用空气/氮气与聚氨酯组合料在一定压力与温度下充分搅拌、混合均匀后,通过泵等输送设备均匀涂抹在可剥离的传送带或传送装置,在其固化成型之前在上面复合瑜珈革、麂皮绒、软木等瑜伽面层、在一定温度下加热使其完全固化,与瑜伽面层贴合在一起,生产出聚氨酯瑜伽垫成品。
Description
技术领域
本发明属于瑜伽垫的技术领域,特别涉及一种聚氨酯瑜珈垫生产工艺。
背景技术
瑜伽垫垫体通常具有三层结构:表层、中间缓冲层及底层,表层通常选自热塑性弹性体层和乳胶层,底层选自热塑性弹性体层,乳胶层和天然橡胶层,中间缓冲层是用特殊的材质,主要对人体进行支撑,起到缓冲作用。
现有聚氨酯生产技术使用聚氨酯化学发泡在模具中生产瑜珈垫缓冲层。主要有以下3种:①预聚体法,预聚体法发泡工艺是将(白料)和(黑料)先制成预聚体,然后在预聚体中加入水、催化剂、表面活性剂、其他添加剂等在高速搅拌下混合进行发泡,固化后在一定温度下熟化即可。②半预聚体法,半预聚体法的发泡工艺是将部分聚醚多元醇组合料(白料)和二异氰酸酯(黑料)先制成预聚体,然后将另一部分的聚醚或聚酯多元醇和二异氰酸酯、水、催化剂、表面活性剂、其他添加剂等加入,在高速搅拌下混合进行发泡。③一步发泡工艺,将聚醚或聚酯多元醇(白料)和多异氰酸酯(黑料)、水、催化剂、表面活性剂、发泡剂、其他添加剂等原料一步加入,在高速搅拌下混合后进行发泡。
如专利申请201710810860.5公开了一种环保型水性聚氨酯垫子的生产方法。一种环保型水性聚氨酯垫子的生产方法,该方法包括以下的步骤:摇粒绒布采用竹醋液浸泡,使摇粒绒布浸透竹醋液,然后挤干;摇粒绒布进行喷涂水性聚氨酯涂料,在摇粒绒布表面凝固形成水性聚氨酯层,挤干;挤干后,进入竹醋液进行发泡,形成多孔性的聚氨酯涂层;发泡完成后水洗,干燥制得所述的水性聚氨酯垫子。
现有市场主流高性能瑜伽垫为橡胶瑜伽垫,与传统橡胶制品生产工艺雷同,从原材料准备-塑炼-混炼-成型-硫化-修整-检验,通常有天然橡胶与合成橡胶两种。天然橡胶瑜伽垫相对异味小、对身体危害小,但价格高昂且产量较低。
目前,传统聚氨酯发泡原理:(多元醇+异氰酸酯+水→聚氨酯脲+二氧化碳气体)。二氧化碳气体使聚氨酯发泡,有时为了增加聚氨酯的发泡倍率而加入环戊烷、二氯甲烷等低沸点溶剂,加热至沸点,使其体积膨胀而提高发泡倍率。这种发泡的缺点有:1、使用溶剂而产生环境污染2、溶剂的挥发会产生安全隐患3、发泡后形成的聚氨酯泡沫结构不均匀,无法控制其具体规格,必须在生产完成后进行打磨、切割等后续操作。4、产品的生产需要使用模具,不能连续性地进行大规模生产。5、发泡原理通过水发泡会产生二氧化碳气体,进一步加剧温室效应。
发明内容
为解决所述问题,本发明提供一种聚氨酯瑜珈垫生产工艺,该工艺不采用发泡剂,使得聚氨酯瑜伽垫的制备更加环保、安全可靠。
本发明提供一种聚氨酯瑜珈垫生产工艺,该工艺可以严格精确控发泡层的厚度、减少原材料的浪费,易于实现工业化生产。
本发明是这样实现的:
一种聚氨酯瑜珈垫生产工艺,使用空气/氮气与聚氨酯组合料(黑料和白料)在一定压力与温度下充分搅拌、混合均匀后,通过泵等输送设备均匀涂抹在可剥离的传送带或传送装置(特氟隆导带,离型纸等),在其固化成型之前在上面复合瑜珈革、麂皮绒、软木等瑜伽面层、在一定温度下加热使其完全固化,与瑜伽面层贴合在一起,生产出聚氨酯瑜伽垫成品。
进一步,所述黑料为异氰酸酯,白料为聚醚多元醇组合料,在0.1-10MPa的压力和40摄氏度以下的温度下,与空气或氮气在设备输送管路中预混合,经发泡头发泡后,发生反应,从而产生聚氨酯。
本发明的聚氨酯发泡过程是:(聚醚多元醇组合料+异氰酸酯+空气/氮气→聚氨酯)。即聚醚多元醇组合料、异氰酸酯与空气/氮气混合后加入稳定剂,进行物理搅拌均匀后(全程不能有水分子参入其中,若发泡过程中混入水分子,水将与黑料发生化学反应、产生二氧化碳气体,发泡性质就转变为化学发泡,与传统聚氨酯发泡雷同,这样会导致发泡后形成的聚氨酯泡沫结构不均匀,无法在特氟隆导带上生产连续化的结构稳定、具有相同特性(硬度、弹性等指标相同)、表面平整的聚氨酯制品。因此去除水分子能够避免水分子与黑料发生反应,控制反应方向,使产生的聚氨酯泡沫结构均匀、稳定,聚氨酯发泡形成的产品表面平整)加热固化。混合发泡时搅拌转速维持在200-1000rpm、压力维持在0.1-10mpa,混合后放出聚氨酯胶涂于运转的特氟龙带上,在20s-2min的固化时间内完成与瑜伽垫面层的复合。
所述稳定剂,为聚氧乙烯醚类表面活性剂。
本发明的有益效果在于:
1.本发明不使用任何物理发泡剂(如环戊烷,二氯甲烷等),不产生环境污染,生产过程中更加安全;
2.本发明不使用水作发泡剂,不产生碳排放;能够避免水分子与黑料发生反应,控制反应方向,使产生的聚氨酯泡沫结构均匀、稳定,聚氨酯发泡形成的产品表面平整;
3.本发明生产过程中可以不使用任何模具,可实现连续化大规模生产聚氨酯卷材;
4.本发明生产过程中可以严格精确控发泡层的厚度、减少原材料的浪费,提高生产效率,使产品与所需规格完全一致,也提高了产品质量。
具体实施方式
为了使本发明的目的、技术方案及优点更加清楚明白,以下结合实施例,对本发明进行进一步详细说明。应当理解,此处所描述的具体实施例仅仅用以解释本发明,并不用于限定本发明。
申请人研究发现:与传统的聚氨酯发泡相比较,传统的发泡必须有水的参与,进而产生化学反应,发泡过程是化学反应产生的转换,而本发明在黑料和白料的混合以及整个生产过程中都不能有水分子的参与(必须无水),去除水分子能够避免水分子与黑料发生反应,控制反应方向,使产生的聚氨酯泡沫结构均匀、稳定,聚氨酯发泡形成的产品表面平整。这是与传统发泡的本质区别。
因此,生产聚氨酯的过程中发泡的原理已经彻底改变;对环境更友好,生产更安全;可以不使用模具,实现连续化生产。
为此,本发明所实现的聚氨酯瑜珈垫生产工艺,使用空气/氮气与聚氨酯组合料(黑料和白料)在一定压力与温度下充分搅拌、混合均匀后,通过泵等输送设备均匀涂抹在可剥离的传送带或传送装置(特氟隆导带,离型纸等),在其固化成型之前在上面复合瑜珈革、麂皮绒、软木等瑜伽面层、在一定温度下加热使其完全固化,与瑜伽面层贴合在一起,生产出聚氨酯瑜伽垫成品。
所述黑料为异氰酸酯,白料为聚醚多元醇组合料,在0.1-10MPa的压力和40摄氏度以下的温度下,与空气或氮气在设备输送管路中预混合,经发泡头发泡后,发生反应,从而产生聚氨酯。
具体地说,聚醚多元醇组合料、异氰酸酯与空气/氮气混合后加入稳定剂,进行物理搅拌均匀后(全程不能有水分子参入其中)加热固化。混合发泡时搅拌转速维持在200-1000rpm、压力维持在0.1-10mpa,混合后放出聚氨酯胶涂于运转的特氟龙带上,在20s-2min的固化时间内完成与瑜伽垫面层的复合。
所述稳定剂,为聚氧乙烯醚类表面活性剂。
本发明主要的优点体现在:
1.仅需黑料和白料与空气即可发泡、发泡流程更简便。
2.无需使用磨具进行生产,可直接连续性生产所需规格的聚氨酯卷材。
3.生产过程中减少了碳排放,促进当下社会经济发展过程中碳中和目标的实现。在既能促进经济发展的前提下又能具有环境保护作用。
4.生产出的聚氨酯瑜伽垫拥有不亚于橡胶瑜伽垫的高弹性和高耐用性,既拥有天然橡胶的健康环保的优势、又能解决正宗天然橡胶生产规模有限、售价高昂等缺陷。
5、使用本工艺生产出的聚氨酯泡沫结构规则,规格厚度可直接控制、精确到毫米。20s-2min固化后从特氟龙带上剥离即为最终成品可直接出厂(无需像传统发泡后对聚氨酯泡沫打磨加工才能出厂。)
且,传送带或传送装置(特氟隆导带,离型纸等)可使用模具替代。将与空气/氮气混合均匀的聚氨酯组合粒涂抹在瑜珈垫面层上,在一定温度下烘干,脱模即可。但使用模具将使生产产量大打折扣,无法高效连续化生产。
总之,从环保的角度来讲本发明在发泡环节不使用发泡剂,可以节能减排、减少碳排放和其他对环境的污染。从生产角度来讲,本发明不用使用生产模具,生产可以更加高效连续性地生产,能够直接与瑜伽面料贴合。从产品的角度来讲,本发明生产出的聚氨酯垫层同时具有高弹性、无异味等特性,可有效地代替市场上常见的橡胶瑜伽垫,减轻污染。与传统聚氨酯发泡相比,本发明在生产过程中不会因加入溶剂而产生有毒有害气体的挥发进而影响生产安全。生产的安全性能更加可靠。
以上仅为本发明的较佳实施例而已,并不用以限制本发明,凡在本发明的精神和原则之内所作的任何修改、等同替换和改进等,均应包含在本发明的保护范围之内。
Claims (5)
1.一种聚氨酯瑜珈垫生产工艺,其特征在于使用空气/氮气与聚氨酯组合料(黑料和白料)在一定压力与温度下充分搅拌、混合均匀后,通过泵等输送设备均匀涂抹在可剥离的传送带或传送装置,在其固化成型之前在上面复合瑜珈革、麂皮绒、软木等瑜伽面层、在一定温度下加热使其完全固化,与瑜伽面层贴合在一起,生产出聚氨酯瑜伽垫成品。
2.如权利要求1所述的聚氨酯瑜珈垫生产工艺,其特征在于所述黑料为异氰酸酯,白料为聚醚多元醇组合料,在0.1-10MPa的压力和40摄氏度以下的温度下,与空气或氮气在设备输送管路中预混合,经发泡头发泡后,发生反应,从而产生聚氨酯。
3.如权利要求2所述的聚氨酯瑜珈垫生产工艺,其特征在于混合后,进行物理搅拌,搅拌均匀后加热固化,从而产生聚氨酯;其中,全程不能有水分子参入其中。
4.如权利要求3所述的聚氨酯瑜珈垫生产工艺,其特征在于混合时搅拌转速维持在200-1000rpm、压力维持在0.1-10mpa。
5.如权利要求4所述的聚氨酯瑜珈垫生产工艺,其特征在于混合后放出聚氨酯胶涂于运转的特氟龙带上,在20s-2min的固化时间内完成与瑜伽垫面层的复合。
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