TWI523627B - A manufacturing method of rubber floor mat - Google Patents

Description

Rubber floor mat manufacturing method

The present invention relates to a rubber floor mat, and more particularly to a method of making a rubber floor mat.

At present, the common rubber floor mats usually include raw rubber and other functional additives, wherein the raw rubber accounts for a large proportion of the material cost of the rubber mat. Raw rubber and other functional additives are mixed and vulcanized to form rubber mats by extrusion or extraction.

In general, a rubber mat produced by extrusion molding or extraction molding tends to cause a problem that the size of the rubber mat does not match. In addition, in the process of making rubber mats, a large amount of raw rubber is often required. In this regard, some industries are looking for ways to reduce the amount of raw rubber in rubber mats.

Embodiments of the present invention provide a method for manufacturing a rubber floor mat, which is used to reduce the amount of raw rubber used and achieve the function of environmentally friendly recycling.

Embodiments of the present invention provide a method of manufacturing a polymer cloth, the method of manufacturing the polymer cloth comprising providing a base fabric having a first surface and a second surface opposite the first surface. The first rubber material is calendered on the first surface to form a first rubber layer, wherein the first rubber material comprises recycled rubber particles. Next, the second rubber material is calendered onto the first rubber layer to form a second rubber layer, wherein the second rubber material includes recycled rubber particles. Thereafter, the textured paper is applied over the second rubber layer. Thereafter, the base fabric, the first rubber layer, the second rubber layer, and the textured paper are laminated. Then, the base fabric and the texture paper are removed.

In summary, the first rubber material and the second rubber material of the embodiment of the present invention all include recycled rubber particles, so that the rubber content of the first rubber layer and the second rubber layer can be complemented by the recycled rubber particles, thereby reducing the rubber. The amount of raw rubber used in the mat. Accordingly, the present invention is implemented The rubber floor mats of the example can achieve the functions of reducing cost and recycling.

In order to further understand the technology, method and effect of the present invention in order to achieve the intended purpose, reference should be made to the detailed description and drawings of the present invention. The drawings and the annexed drawings are intended to be illustrative and not to limit the invention.

100‧‧‧Rubber mats

110‧‧‧First rubber layer

120‧‧‧Second rubber layer

130‧‧‧Kib

140‧‧‧Text paper

D1‧‧‧ lower surface

L1, L2‧‧‧ laminate

S101~S106‧‧‧Step procedure

S1‧‧‧ first surface

S2‧‧‧ second surface

U1‧‧‧ upper surface

1 is a schematic structural view of a rubber floor mat according to an embodiment of the present invention.

2 is a flow chart showing a method of manufacturing a rubber floor mat according to an embodiment of the present invention.

3 is a schematic structural view of a semi-finished product formed in a process for manufacturing a rubber floor mat according to an embodiment of the present invention.

FIG. 1 is a schematic structural view of a rubber floor mat according to an embodiment of the present invention. Referring to FIG. 1 , the rubber floor mat 100 includes a first rubber layer 110 and a second rubber layer 120 . The second rubber layer 120 is located above the first rubber layer 110 and is bonded to the first rubber layer 110.

2 is a schematic flow chart of a method of manufacturing a rubber floor mat according to an embodiment of the present invention. 3 is a schematic structural view of a semi-finished product formed in a process for manufacturing a rubber floor mat according to an embodiment of the present invention.

As shown in FIG. 3, the manufacturing method of the rubber floor mat of the embodiment of the present invention mainly forms a first rubber layer 110 on the first surface S1 of the base fabric 130, and then forms a second rubber layer 120 on the first rubber layer 110. Then, the texture paper 140 is attached to the second rubber layer 120, and then the base fabric 130 and the texture paper 140 are removed after co-vulcanization. Accordingly, the rubber floor mat 100 has been substantially formed. It should be noted that the texture of the base fabric 130 and the texture paper 140 is used to provide the surface texture of the rubber mat 100. Therefore, by providing the base fabric 130 and the texture paper 140 having different textures, the rubber mat 100 having different textures can be formed. Next, please refer to FIG. 2 and FIG. 3 together.

Referring to FIG. 2, first, in step S101, the base fabric 130 has a first surface S1 and a second surface S2 opposite to the first surface S1. The first rubber material is a raw rubber that has not undergone a vulcanization reaction. In general, raw rubber has considerable elasticity and lacks plasticity before the vulcanization reaction. Therefore, the first rubber material is not easily stretched by mechanical processing to cause plastic deformation. Accordingly, the base fabric 130 is used as a carrier for the first rubber material, so that the first rubber material is more likely to enter the subsequent processing steps. It should be noted that the base fabric 130 is a fabric, and the material of the base fabric 130 may be cotton, polyester fiber, nylon or a blended knitted fabric of other different constituent fibers, and the user may select different types or different Denny numbers. The fabric is used as the base fabric 130. However, the present invention does not limit the material of the base fabric 130.

Next, in step S102, the first rubber material is calendered on the first surface S1 of the base fabric 130, and the first rubber layer 110 is formed on the base fabric 130. In detail, after the components of the first rubber material are uniformly mixed by a Mixer, a preheating process is performed to facilitate the subsequent calendering bonding process. Then, the first rubber material is pressed and bonded to the base fabric 130 by a calender, so that the first rubber material can be uniformly attached to the first surface S1 of the base fabric 130, thereby forming the first rubber. Layer 110. The thickness of the first rubber layer 110 depends on the pressure of the calendering, and the greater the pressure of the calendering, the thinner the thickness of the first rubber layer 110.

It is worth noting that the first rubber material includes raw rubber and various compounding agents, and these compounding agents can increase the performance of the rubber mat 100. In order to uniformly mix the various components of the first rubber material, the first rubber material is kneaded by a mixer.

The composition ratio of the first rubber material is detailed in Table 1 below.

It is worth noting that in the process of making the rubber mat 100, some functional additives are added almost in accordance with the user's demand for the rubber mat 100. In this embodiment, the first oak The rubber material includes 10 to 30 parts by weight (PHR) of recycled rubber particles, and the recycled rubber particles are rubber particles made of a waste rubber material. The recovered rubber particles are mixed with other components of the first rubber material through a compacting machine to increase the rubber content of the first rubber material. Further, the first rubber material includes conductive carbon black, whereby the first rubber layer 110 can conduct electric charges.

Next, in step S103, the second rubber material is calendered on the first rubber layer 110, thereby forming the second rubber layer 120 on the first rubber layer 110. Specifically, in the same manner, a component of the second rubber material is first uniformly mixed by a molding machine, and then a preheating process is performed. Next, the second rubber material is calendered and attached to the first rubber layer 110 by a lighter to form a second rubber layer 120.

The composition ratio of the second rubber material is detailed in Table 2 below.

In this embodiment, the second rubber material includes 4 to 10 parts by weight (PHR) of recycled rubber particles. Similarly, the recovered rubber particles are rubber particles made of a waste rubber material. The recycled rubber particles are mixed with other components of the second rubber material through a compacting machine to increase the rubber content of the second rubber material. In addition, after the other components of the second rubber material are mixed, the recycled rubber particles may be sprinkled on the second rubber material of the other components after the mixing, whereby the rubber particles may be recovered as a second after the subsequent rolling process. The surface pattern of the rubber layer 120.

Further, the second rubber material includes an antistatic liquid and has a function of electrostatic discharge. According to this, the second rubber layer 120 can transfer the electrostatic charge to the first rubber layer 110 to conduct electrostatic charge conduction. To the ground.

After the step S103, the base fabric 130, the first rubber material layer 110, and the second rubber material layer 120 are collectively wound up by a winder and a laminate L1 is formed. It should be noted that the fine mica powder or the talcum powder may be sprinkled on the surface of the second rubber material layer 120 before the winding machine performs the winding, so that the base fabric 130 of the laminated layer L1 can be lowered during winding. The case where the first rubber material layer 110 and the second rubber material layer 120 are improperly adhered.

Subsequently, in step S104, the texture paper 140 is attached over the second rubber layer 120. Specifically, the texture paper is attached to the second rubber layer 120 through a press vulcanizer, and then the press vulcanizer presses the base fabric 130, the first rubber layer 110, the second rubber layer 120, and the texture paper 140 together. Combine to form a laminate L2. The pressure of calendering performed by the press vulcanizer is between 50 and 80 kg/cm 2 (kg/cm ² ), and the press vulcanizer can eliminate the base fabric 130, the first rubber material layer 110, and the second rubber material layer. The bubbles between the 120 and the textured paper 140 allow the laminate L2 to be uniform and flat. Further, the thickness of the laminate L2 depends on the pressure applied by the press vulcanizer, and the greater the pressure of the calendering, the thinner the thickness of the laminate L2.

It should be noted that the texture paper 140 is used to provide a texture of the rubber floor mat 100, and the texture of the rubber floor mat 100 is printed on the surface of the second rubber layer 120. In this way, the user can select different textures of the paper 140 to be printed on the rubber mat 100 according to different designs.

Then, in step S105, the base fabric 130, the first rubber layer 110, the second rubber layer 120, and the texture paper 140 are co-vulcanized. In detail, the press vulcanizer transports the laminate L2 at a production rate of between 0.1 m/min and 0.8 m/min. It is worth noting that the press vulcanizer can continuously output the laminate L2 instead of the sheet-like production, so that it is easy to adjust the width and length of the desired laminate L2. Compared with the conventional floor mat, the rubber floor mat 100 does not need to be assembled in multiple pieces, but can be laid on the floor in whole pieces, thereby increasing the convenience of laying. Next, the laminate L2 is subjected to a vulcanization reaction through a press vulcanizer, and the vulcanization temperature is between 100 degrees Celsius (° C.) and 170 degrees Celsius (° C.).

Then, in step S106, the base fabric 130 and the texture paper 140 are removed. Specifically, after the vulcanization reaction is performed on the laminate L2, the base fabric 130 and the texture paper 140 are removed. Accordingly, the rubber floor mat 100 has been substantially formed.

Specifically, the upper surface U1 of the rubber floor mat 100 has the texture provided by the texture paper 140, and the lower surface D1 of the rubber mat 100 has the texture provided by the base fabric 130. It should be noted that when the user can apply the adhesive on the lower surface D1 and the adhesive adheres to the texture of the lower surface D1, the rubber mat 100 can be laid on the ground through the adhesive. The texture of the upper surface U1 can provide a frictional force for the user to walk on the rubber floor mat 100.

In summary, the first rubber material and the second rubber material of the embodiment of the present invention both include recycled rubber particles, which are rubber particles made of waste rubber material, and the recycled rubber particles pass through the compacting machine and The first rubber material and other components of the second rubber material are mixed. Therefore, the rubber content of the first rubber layer and the second rubber layer can be complemented by the recycled rubber particles, thereby reducing the amount of raw rubber used in the rubber mat. Accordingly, the rubber floor mat of the embodiment of the invention can achieve the function of reducing the cost of the rubber floor mat and recycling the environment.

The above is only an embodiment of the present invention, and is not intended to limit the scope of the invention. It is still within the scope of patent protection of the present invention to make any substitutions and modifications of the modifications made by those skilled in the art without departing from the spirit and scope of the invention.

100‧‧‧Rubber mats

110‧‧‧First rubber layer

120‧‧‧Second rubber layer

D1‧‧‧ lower surface

U1‧‧‧ upper surface

Claims (8)

A manufacturing method of a rubber floor mat comprising: providing a base fabric having a first surface and a second surface opposite to the first surface; calendering a first rubber material on the first surface to form a first rubber layer, wherein the first rubber material comprises recycled rubber particles; calendering a second rubber material on the first rubber layer, thereby forming a second rubber layer, wherein the second rubber material comprises recycled rubber particles Laminating a paper on the second rubber layer; co-vulcanizing the base fabric, the first rubber layer, the second rubber layer, and the texture paper; and removing the base fabric and the texture paper. The method of manufacturing a rubber floor mat according to claim 1, wherein the paper is adhered to the second rubber layer by a press vulcanizer. The method of manufacturing a rubber floor mat according to claim 1, wherein the first rubber material comprises 10 to 30 phr of recycled rubber particles, and the first rubber material is mixed by a compacting machine and then calendered and laminated. On the first surface of the base fabric. The method of manufacturing a rubber floor mat according to claim 1, wherein the second rubber material comprises 4 to 10 phr of recycled rubber particles, and the second rubber material is mixed by a compacting machine and then calendered and laminated. On the first rubber layer. The method of manufacturing a rubber floor mat according to claim 1, wherein the base fabric, the first rubber layer, the second rubber layer, and the textured paper are subjected to a vulcanization reaction by a press vulcanizer. The method for manufacturing a rubber floor mat according to claim 5, wherein the base fabric, the first rubber layer, the second rubber layer, and the texture paper have a vulcanization temperature of between 100 degrees Celsius and 170 degrees Celsius. between. The method for manufacturing a rubber floor mat according to claim 5, wherein the press vulcanizer has a total of the base fabric, the first rubber layer, the second rubber layer, and the textured paper. The same calendering pressure is between 50 kg/cm2 and 80 kg/cm2. The method for manufacturing a rubber floor mat according to claim 5, wherein the base fabric, the first rubber layer, the second rubber layer, and the grain paper are collectively output by the press vulcanizer The speed of production ranges from 0.1 m/min to 0.8 m/min.