WO2016134568A1 - Self-skinning anti-fatigue floor mat and preparation process therefor - Google Patents

Abstract

A self-skinning anti-fatigue floor mat, comprising a mat body (1) which is integrally formed from polyurethane and comprises an upper surface layer (11), an inner core layer (12) and a lower surface layer (13), wherein the upper surface layer (11) and the lower surface layer (13) are both high density polyurethane layers, and the inner core layer (12) is a low-density polyurethane layer. A preparation process therefor comprises: step 1, wiping a mould cavity clean; step 2, successively spraying a mould releasing agent and an in-mould paint on the mould cavity; step 3, introducing a cooling medium into the mould with the temperature of the mould being controlled at 20-30ºC, and then injecting a polyurethane raw material into the mould cavity for a foaming reaction; step 4, closing the mould; step 5, shaking the mould; step 6, when the mould cavity is fully filled with the polyurethane raw material, changing the cooling medium to a heating medium to increase the temperature to 40-120ºC within 1 minute; and step 7, after the polyurethane raw material is cured in the mould, opening the mould and taking out a product. The floor mat has low costs, strong comfort level, good quality in use and high production efficiency.

Description

Self-skinning anti-fatigue mat and preparation process thereof Technical field

The invention relates to a floor mat, in particular to a self-skinning anti-fatigue mat and a preparation process thereof.

Background technique

With the development of the national economy and the improvement of living standards, interior decoration, especially soft decoration, has become a new fashion trend. The floor mats in the ground decoration play a very important role in the home and in hotels, office buildings, public entertainment and other places. The floor mats are divided into dust-removing mats, water-absorbing mats, non-slip mats and anti-fatigue mats according to their functions. Among them, the anti-fatigue mat is popular among consumers because of its special function, and has been widely used.

In the prior art, the anti-fatigue mat is generally divided into a composite material floor mat and a polyurethane floor mat, and the composite material floor mat includes a polyvinyl chloride PVC layer, an EPDM EPDM layer and a rubber layer in order from top to bottom. However, the composite floor mat has several disadvantages: 1. High manufacturing cost, complicated process, and low production efficiency; 2. The multi-layer composite structure is formed by bonding adhesives, so that it is easy to delamination and crack, and shorten the service life; 3, because the surface of the product is PVC layer, PVC layer is easy to age and easy to precipitate additives, resulting in hardening of the mat, reducing the service life; 4, the product is easy to absorb water, easy to mold and bacteria, not convenient to clean. Conventional polyurethane mats are mostly made of a single layer of uniform polyurethane material. The density of polyurethane materials is usually low (density is 200-400Kg/M ³ ). Although the production process is relatively simple, the surface strength is low. When it is in contact with high heels for a long time, the surface is easily damaged, which affects the quality of use of the product.

In view of this, the inventors have specially designed a self-skinning anti-fatigue mat and a preparation process thereof, and the present invention is produced.

Summary of the invention

One of the objects of the present invention is to provide a self-skinning anti-fatigue mat to save production costs, improve the comfort of use, and improve the quality and performance of the product.

Another object of the present invention is to provide a preparation process of a self-skinning anti-fatigue mat to optimize the processing technology and improve production efficiency.

In order to achieve the above object, the technical solution of the present invention is as follows:

A self-skinning anti-fatigue mat comprises a floor mat body, wherein the mat body is integrally formed of polyurethane, and the mat body comprises an upper surface layer, an inner core layer and a lower surface layer, wherein the upper surface layer and the lower surface layer are both high density The polyurethane layer has an inner core layer of a low density polyurethane layer.

The upper surface layer and the lower surface layer have a density of 500-1000 Kg/M ³ .

The upper surface layer and the lower surface layer have a density of 800 Kg/M ³ .

The inner core layer has a density of 20 to 200 Kg/M ³ .

The inner core layer has a density of 60 kg/M ³ .

A preparation process of a self-skinning anti-fatigue mat comprises the following steps:

Step 1. Wipe the mold cavity with a clean white cloth;

Step 2, spraying a layer of release agent and a layer of in-mold paint on the mold cavity;

Step 3, the mold is introduced into the refrigerant, and the mold temperature is controlled at 20-30 ° C; then the polyurethane raw material is injected into the mold cavity for foaming reaction;

Step 4, clamping the mold and locking the mold;

Step 5, shaking the mold;

Step 6. After the polyurethane raw material fills the mold cavity, the refrigerant is replaced with a heat medium to make the mold The temperature of the appliance is raised to 40-120 ° C in 1 minute;

Step 7. After the polyurethane raw material is matured in the mold, the product is opened and the product is removed, and then the trimming product and the mold are cleaned to complete the preparation process of the whole product, and the curing time is less than 15 minutes.

The polyurethane raw material comprises an A component (polyether polyol and an auxiliary) and a B component (isocyanate), and the mass ratio of the B component/A component is 0.2-0.5; the A component and the B component are at a temperature of 20- The reaction was mixed at 30 °C.

The component A is prepared from the following raw materials in parts by weight: 100 parts of polyether polyol, 2-8 parts of crosslinking agent, 1-2.5 parts of composite catalyst, 0.5-1 part of surfactant, foaming agent 10 -20 servings.

The B component is a one-component isocyanate or a multi-component isocyanate.

After adopting the above scheme, the present invention has the following advantages:

1. Since the upper surface layer and the lower surface layer are made of high-density polyurethane, the surface strength of the product is improved and the damage is less likely to occur, thereby enhancing the tear resistance and durability of the product, and the performance of the product is remarkably improved. index;

Second, the inner core layer of the invention is made of low-density polyurethane, which ensures the flexibility and comfort of the product, improves the resilience and cushioning property of the product, thereby enhancing the anti-fatigue effect of the product and alleviating the blood circulation of the human foot. Stress, reduce physical fatigue;

3. The floor mat body of the invention is integrally formed of polyurethane, which not only saves processing cost, improves production efficiency, but also prolongs the service life of the product, and avoids delamination of the product due to cold weather, overheating or frequent use. Cracking phenomenon. At the same time, the product also has the characteristics of non-absorbent water, which prevents the product from being mildewed and bacteria-producing due to water absorption, further enhancing the performance of the product.

The invention will be further described below in conjunction with the drawings and specific embodiments.

DRAWINGS

Figure 1 is a schematic view of the structure of the present invention;

Figure 2 is a schematic structural view of the cold heat exchange system of the present invention.

Label description

Floor mat body 1, upper surface layer 11, inner core layer 12, lower surface layer 13, cold heat exchange system 2, heating box 21, cooling box 22, first duct 23, second duct 24, third duct 25, Four conduits 26, a first pump 27, and a second pump 28.

detailed description

As shown in FIG. 1 , a self-skinning anti-fatigue mat disclosed in the present invention comprises a floor mat body 1 , and the mat body 1 is integrally formed of polyurethane. The mat body 1 includes an upper surface layer 11 , an inner core layer 12 , and The lower surface layer 13, the upper surface layer 11 and the lower surface layer 13 are both high density polyurethane layers, and the inner core layer 12 is a low density polyurethane layer.

To make products with better performance, on the surface layer of this embodiment and the embodiment 11 of the lower density of the surface layer 13 are 500-1000Kg / M ^3, the density of the core layer 12 is 20-200Kg / M ^3. When the density of the surface layer 11 and a lower surface layer 13 are 800Kg / M ^3, the density of the core layer 12 is 60Kg / M ^3, the product of the performance indicators are to achieve the best state.

The invention prepares a self-skinning anti-fatigue mat, which comprises the following steps:

Step 1. Wipe the mold cavity with a clean white cloth;

Step 2, spraying a layer of release agent and a layer of in-mold paint on the mold cavity;

Step 3, the mold is introduced into the refrigerant, and the mold temperature is controlled at 20-30 ° C; then the polyurethane raw material is injected into the mold cavity for foaming reaction;

Step 4, clamping the mold and locking the mold;

Step 5, shaking the mold;

Step 6, after the polyurethane raw material fills the mold cavity, the refrigerant is replaced by a heat medium, so that the temperature of the mold is raised to 40-120 ° C in 1 minute;

Step 7. After the polyurethane raw material is matured in the mold, the product is opened by mold removal (ie, curing), and then the trimming product and the mold are cleaned to complete the preparation process of the whole product, and the curing time is less than 15 minutes.

In the present invention, as shown in FIG. 2, both the refrigerant and the heat medium are in the cold heat exchange system 2, and the cold heat exchange system 2 includes a heating tank 21, a cooling tank 22, a first duct 23, a second duct 24, and a The three pipes 25 and the fourth pipe 26, the heat medium and the refrigerant are respectively placed in the heating tank 21 and the cooling tank 22, and the first pipe 23 and the third pipe 25 are both connected to the heating tank 21 and the mold, the second pipe 24 and the fourth pipe 26 is connected to the cooling box 22 and the mold, the first pipe 23 and the third pipe 25 are provided with a solenoid valve A and a solenoid valve C, and the second pipe 24 and the fourth pipe 26 are respectively provided with a solenoid valve B and a solenoid valve D, A first pump 27 and a second pump 28 are provided on the third duct 25 and the fourth duct 26, respectively. In use, the cold heat exchange system 2 controls the ingress and egress of the heat medium and the refrigerant by the cooperation between the four solenoid valves, thereby adjusting the temperature of the mold.

The principle of the invention is that the polyurethane foaming reaction is an exothermic reaction, and the foaming agent added to the polyurethane raw material is boiled and expanded by heat. When the foamed polyurethane raw material hits the inner wall of the low temperature mold, the foaming agent recondenses and It becomes a liquid, so that the polyurethane raw material is condensed on the inner wall of the mold into a dense skin (i.e., the upper surface layer 11 and the lower surface layer 13). The lower the mold temperature, the denser and thicker the skin, and the lower the density of the inner core layer 12. Thus, a self-skinning product having a dense skin and a low density of the inner core layer is produced. At the same time, since the low temperature of the mold easily causes the polyurethane raw material to react too slowly and reduces the production efficiency, the present invention rapidly raises the mold temperature after the polyurethane raw material is solidified to accelerate the product ripening speed, thereby improving the production efficiency.

In order to make the product have better performance index, the polyurethane raw material includes the A component (polyether polyol and auxiliary material) and the B component (isocyanate), and the mass ratio of the B component/A component is 0.2-0.5; The component B is mixed at a temperature of 20 to 30 °C. Among them, the A component is prepared from the following raw materials in parts by weight: 100 parts of polyether polyol, 2-8 parts of crosslinking agent, 1-2.5 parts of composite catalyst, 0.5-1 part of surfactant, foaming agent 10 -20 servings. Among them, the isocyanate may be a one-component isocyanate or a multi-component isocyanate. The self-skinning anti-fatigue mat made of the polyurethane raw material has the following performance indexes.

Table 1 Performance indicators of self-skinning anti-fatigue mats

project	unit	Performance
			hardness	HSA	15-70
Epidermal density	Kg/M 3	500-1000
			Inner core density	Kg/M 3	20-200
Tensile Strength	Mpa	≥0.20
			Elongation at break	%	≥50
Tear strength	N/mm	≥0.20

Embodiment 1:

The A component and the B component were reacted at a temperature of 30 ° C to obtain a polyurethane of this example. Among them, the A component is prepared from the following raw materials in parts by weight: 100 parts of polyether polyol (80 parts of polyether polyol (Mn=5000), 20 parts of polymer polyol), 3 parts of crosslinking agent, compound 1.02 parts of catalyst (1 part of amine catalyst, 0.02 of metal catalyst) Part) 0.7 parts of surfactant (0.7 part of silane surfactant), 15 parts of foaming agent; component B is isocyanate, and mass ratio of component B/component is 0.3-0.34.

A process for preparing a self-skinning anti-fatigue mat comprising the following steps:

Step 1. Wipe the mold cavity with a clean white cloth;

Step 2, spraying a layer of release agent and a layer of in-mold paint on the mold cavity;

Step 3, the mold is introduced into the refrigerant, and the mold temperature is controlled at 20 ° C; then the polyurethane raw material is injected into the mold cavity for foaming reaction;

Step 4, clamping the mold and locking the mold;

Step 5, shaking the mold, so that the injected polyurethane flows uniformly in the mold cavity to ensure uniform density of various parts of the product and prevent bubbles from appearing inside the product;

Step 6, after the polyurethane raw material fills the mold cavity, the refrigerant is replaced with a heat medium, so that the temperature of the mold is raised to 80 ° C in 1 minute;

Step 7. After the polyurethane raw material is matured in the mold, the product is opened and the product is removed, and then the trimming product and the mold are cleaned to complete the preparation process of the whole product, and the curing time is 10 minutes. The test results are as follows:

Table 2 Performance indicators of surface coating

project	unit	Performance
			hardness	HSA	20
Epidermal density	Kg/M 3	600
			Inner core density	Kg/M 3	120
Tensile Strength	Mpa	0.30
			Elongation at break	%	80
Tear strength	N/mm	0.30

Embodiment 2:

The A component and the B component were reacted at a temperature of 30 ° C to obtain a polyurethane of this example. Among them, the A component is prepared from the following raw materials in parts by weight: 100 parts of polyether polyol (70 parts of polyether polyol (Mn=5000), 30 parts of polymer polyol), 5 parts of crosslinking agent, compound 1.02 parts of catalyst (1 part of amine catalyst, 0.02 parts of metal catalyst), 0.7 part of surfactant (0.7 part of silane surfactant), 15 parts of foaming agent; component B is isocyanate, component B/component A The mass ratio is 0.34-0.38.

A process for preparing a self-skinning anti-fatigue mat comprising the following steps:

Step 1. Wipe the mold cavity with a clean white cloth;

Step 2, spraying a layer of release agent and a layer of in-mold paint on the mold cavity;

Step 3, the mold is introduced into the refrigerant, and the mold temperature is controlled at 25 ° C; then the polyurethane raw material is injected into the mold cavity for foaming reaction;

Step 4, clamping the mold and locking the mold;

Step 5, shaking the mold, so that the injected polyurethane flows uniformly in the mold cavity to ensure uniform density of various parts of the product and prevent bubbles from appearing inside the product;

Step 6, after the polyurethane raw material fills the mold cavity, the refrigerant is replaced by a heat medium, so that the temperature of the mold is raised to 120 ° C in 1 minute;

Step 7. After the polyurethane raw material is matured in the mold, the product is opened and the product is removed, and then the trimming product and the mold are cleaned to complete the preparation process of the whole product, and the curing time is 5 minutes. The test results are as follows:

Table 3 Performance indicators of surface coating

project	unit	Performance
			hardness	HSA	35

Epidermal density	Kg/M 3	700
			Inner core density	Kg/M 3	100
Tensile Strength	Mpa	0.35
			Elongation at break	%	80
Tear strength	N/mm	0.30

Embodiment 3:

The A component and the B component were reacted at a temperature of 30 ° C to obtain a polyurethane of this example. Among them, the A component is prepared from the following raw materials in parts by weight: 100 parts of polyether polyol (60 parts of polyether polyol (Mn=5000), 40 parts of polymer polyol), 8 parts of crosslinking agent, compound 1.02 parts of catalyst (1 part of amine catalyst, 0.02 parts of metal catalyst), 0.7 part of surfactant (0.7 part of silane surfactant), 15 parts of foaming agent; component B is isocyanate, component B/component A The mass ratio is 0.36-0.40.

A process for preparing a self-skinning anti-fatigue mat comprising the following steps:

Step 1. Wipe the mold cavity with a clean white cloth;

Step 2, spraying a layer of release agent and a layer of in-mold paint on the mold cavity;

Step 3, the mold is introduced into the refrigerant, and the mold temperature is controlled at 30 ° C; then the polyurethane raw material is injected into the mold cavity for foaming reaction;

Step 4, clamping the mold and locking the mold;

Step 5, shaking the mold, so that the injected polyurethane flows uniformly in the mold cavity to ensure uniform density of various parts of the product and prevent bubbles from appearing inside the product;

Step 6, after the polyurethane raw material fills the mold cavity, the refrigerant is replaced by a heat medium, so that the temperature of the mold is raised to 40 ° C in 1 minute;

Step 7, after the polyurethane raw material is matured in the mold, the product is opened and the product is removed, and then trimmed. After the product and mold are cleaned, the preparation process of the entire product is completed, and the curing time is 12 minutes. The test results are as follows:

Table 4 Performance indicators of surface coating

project	unit	Performance
			hardness	HSA	35
Epidermal density	Kg/M 3	800
			Inner core density	Kg/M 3	60
Tensile Strength	Mpa	0.45
			Elongation at break	%	100
Tear strength	N/mm	0.50

The invention has the following advantages:

1. Since the upper surface layer 11 and the lower surface layer 13 are made of high-density polyurethane, the surface strength of the product is improved, and damage is less likely to occur, thereby enhancing the tear resistance and durability of the product, and the product is remarkably improved. Performance indicators;

2. The inner core layer 12 of the present invention is made of low-density polyurethane, which ensures the flexibility and comfort of the product, improves the resilience and cushioning property of the product, thereby enhancing the anti-fatigue effect of the product and relieving the blood of the human foot. Circulation pressure to reduce physical fatigue;

3. The floor mat body 1 of the invention is integrally formed of polyurethane, which not only saves processing cost, improves production efficiency, but also prolongs the service life of the product, and avoids the occurrence of products due to cold weather, overheating or frequent use. The phenomenon of layer cracking. At the same time, the product also has the characteristics of non-absorbent water, which prevents the product from being mildewed and bacteria-producing due to water absorption, further enhancing the performance of the product.

The above embodiments and drawings do not limit the product form and style of the present invention. Appropriate changes or modifications made by those skilled in the art should be considered as not departing from the scope of the invention.

Claims (8)

1. A self-skinning anti-fatigue mat is characterized in that it comprises a floor mat body, and the mat body is integrally formed of polyurethane, and the mat body comprises an upper surface layer, an inner core layer and a lower surface layer, an upper surface layer and a lower surface layer. Both are high density polyurethane layers and the inner core layer is a low density polyurethane layer.
2. The self-skinning anti-fatigue mat according to claim 1, wherein the upper surface layer and the lower surface layer have a density of 500 to 1000 Kg/M ³ .
3. The self-skinning anti-fatigue mat according to claim 2, wherein the upper surface layer and the lower surface layer have a density of 800 Kg/M ³ .
4. A self-skinning anti-fatigue mat according to claim 1, wherein said inner core layer has a density of from 20 to 200 kg/m ³ .
5. Since the crust of claim 4, wherein the anti-fatigue mats, characterized in that: said inner core layer having a density of 60Kg / M ^3.
6. A process for preparing a self-skinning anti-fatigue mat according to claim 1, characterized in that it comprises the following steps:

   Step 1. Wipe the mold cavity with a clean white cloth;

   Step 2, spraying a layer of release agent and a layer of in-mold paint on the mold cavity;

   Step 3, the mold is introduced into the refrigerant, and the mold temperature is controlled at 20-30 ° C; then the polyurethane raw material is injected into the mold cavity for foaming reaction;

   Step 4, clamping the mold and locking the mold;

   Step 5, shaking the mold;

   Step 6, after the polyurethane raw material fills the mold cavity, the refrigerant is replaced by a heat medium, so that the temperature of the mold is raised to 40-120 ° C in 1 minute;

   Step 7. After the polyurethane raw material is matured in the mold, the product is opened and the product is removed, and then the trimming product and the mold are cleaned to complete the preparation process of the whole product, and the curing time is less than 15 minutes.
7. The self-skinning anti-fatigue mat preparation process according to claim 6, wherein the polyurethane raw material comprises an A component (polyether polyol and an auxiliary material) and a B component (isocyanate), and a B component/A The mass ratio of the components is from 0.2 to 0.5; the components A and B are mixed and reacted at a temperature of 20 to 30 °C.
8. The self-skinning anti-fatigue mat preparation process according to claim 6, wherein the component A is prepared from the following raw materials in parts by weight: 100 parts of polyether polyol, crosslinking agent 2 8 parts, 1-2.5 parts of composite catalyst, 0.5-1 part of surfactant, 10-20 parts of foaming agent.

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