Lattice structured elastomers and elastomeric pads made from lattice structured elastomers

Abstract

The present application relates to a lattice structure elastomer and an elastic pad made of the lattice structure elastomer, wherein the lattice structure elastomer is a thermoplastic elastomer forming different elastic support regions, and the elastic support regions are at least divided into a comfort region and a support region in an XYZ three-axis coordinate system, and the softness formed by the comfort region is greater than the softness formed by the support region. Through the layout of different elastic support regions, the present application not only can provide the required support force, but also can provide the required softness and comfort of the comfort region, and according to the deformation difference of the regions, the air permeability of the lattice structure elastomer itself is maintained, and the stuffiness is avoided.

Description

TECHNICAL FIELD

[0001] The present application belongs to the field of daily necessities, and particularly relates to a crystal lattice structure elastomer, and further relates to an elastic pad made of the crystal lattice structure elastomer. BACKGROUND

[0002] In many occasions requiring buffering and supporting, such as cushion or back cushion, mattress, sofa cushion and the like, an elastomer material with high strength, high elasticity (anti-compression performance), high impact resistance and light weight is required.

[0003] At present, the elastomer formed by 3D printing from thermoplastic powder has been applied to various occasions due to the advantages of simple forming process, environmental protection, high raw material utilization, recyclability and high precision.

[0004] However, in order to meet the needs of mechanical properties and air permeability, the porosity of the elastomer is small and remains the same, so when used as an elastic pad, it has the following defects:

[0005] 1. Since the elastic force provided by the elastomer is relatively balanced and has no soft and hard parts, the elastic pad will either be too concave after being stressed, causing a large deformation area and affecting air permeability, or the deformation will be too small, resulting in insufficient comfort.

[0006] 2. Due to factors such as melt shrinkage, poor bonding between powder particles, and many voids, the mechanical properties (such as anti-compression performance) cannot meet the needs of use. If the anti-compression performance of the elastomer is to be enhanced, the main means is to increase the thickness of the elastomer, so the volume of the formed elastic pad is large. SUMMARY

[0007] The technical problem to be solved by the present application is to overcome the shortcomings of the prior art and provide an improved crystal lattice structure elastomer.

[0008] Meanwhile, the present application also relates to an elastic pad made of the crystal lattice structure elastomer.

[0009] To solve the above technical problems, the present application adopts the following technical solutions:

[0010] A crystal lattice structure elastomer is formed by a thermoplastic elastomer forming different elastic support regions, the elastic support regions are divided into at least a comfort zone and a support zone in an XYZ three-axis coordinate system, and the softness formed by the comfort zone is greater than the softness formed by the support zone.

[0011] Preferably, an elastic resin layer is formed on the thermoplastic elastomer, the elastic resin layer is formed in at least the internal pores of the thermoplastic elastomer and combined with the thermoplastic elastomer, and the thermoplastic elastomer and the elastic resin layer constitute a unit cell structure.

[0012] Briefly, the lattice structure elastomer is contacted with a treatment liquid containing an elastic resin or raw material for forming an elastic resin, a resin curing agent, and heated and cured, and an elastic resin layer is formed in the internal pores of the lattice structure elastomer and on the outer surface of the lattice structure elastomer. The elastic resin is cured, bonded and compounded with the lattice structure elastomer, fills the internal pores of the lattice structure elastomer, and a lattice cell structure with excellent mechanical properties can be obtained. The lattice cell structure has higher compression resistance under the same weight, and the material has lower weight under the same compression resistance. In addition, the elastic resin layer on the outer surface of the lattice structure elastomer can reduce the surface roughness of the material, making the surface of the lattice cell structure smooth.

[0013] According to a specific embodiment and preferred aspect of the present application, the elastic resin layer is also formed on the outer surface of the lattice structure elastomer; or / and, the lattice cell structure requires a pressure greater than 270 N when compressed to a deformation of 50%; or / and, the porosity of the thermoplastic elastomer is 5% to 40%.

[0014] Preferably, the hardness of the elastic resin constituting the elastic resin layer is greater than 50A Shore hardness and less than 40D Shore hardness, the viscosity at 25°C is less than 12000 cP, the tensile strength is greater than 5 MPa, and the elongation at break is greater than 120%.

[0015] Preferably, the mass of the elastic resin layer is 10% to 50% of the mass of the lattice structure elastomer; and / or, the density of the thermoplastic elastomer is 0.7-1.1 g / cm 3 .

[0016] Preferably, the lattice cell structure is formed by coating treatment of the lattice structure elastomer with a treatment liquid containing the elastic resin or raw material thereof, and a curing agent.

[0017] Preferably, the coating treatment method is spraying, dipping or electroplating, and the treatment liquid penetrates into the internal pores of the lattice structure elastomer during the coating treatment.

[0018] In some embodiments, the coating treatment time is 5-20 min, and the heating treatment time is 3-12 h.

[0019] Further, the mass concentration of the elastic resin in the treatment liquid is 30-60%, and the mass concentration of the curing agent is 1%-10%. In some embodiments, the mass concentration of the elastic resin in the treatment liquid is 40-55%, and the mass concentration of the curing agent is 2%-5%.

[0020] In some embodiments, the heating and curing is performed at a temperature of 80-100℃, and the coating treatment and heating and curing are performed once or repeatedly 1-3 times after the first time.

[0021] In addition, the resin constituting the thermoplastic elastomer is one or a combination of both selected from a thermoplastic polyurethane resin and a thermoplastic polyethylene resin.

[0022] In some embodiments of the present application, the elastic resin constituting the elastic resin layer is one or a combination of more than one selected from a polyurethane resin, an acrylic resin, and a silicone resin.

[0023] That is, the lattice structure elastomer is prepared by 3D printing. By adjusting parameters such as 3D printing temperature and laser power, the sintering density and porosity of the lattice structure elastomer can be controlled, and thus the depth and quality of the penetration of the elastic resin can be controlled. The lower the temperature and laser power, the higher the porosity of the printed lattice structure elastomer, the higher the content of the elastic resin in the lattice structure, and the better the compression resistance of the lattice structure.

[0024] In some embodiments, the parameters used are as follows: temperature 80-140℃, laser power 30-100W, scanning speed 4000-12000mm / s, and scanning interval 0.1-0.3mm.

[0025] Meanwhile, the lattice cell structure constituting the lattice structure elastomer is not particularly limited. The lattice cell structure can be a common cube, star, octagon, hexagon, rhombus, tetrahedron, etc.

[0026] Another technical solution of the present application is an elastic pad comprising a lattice structure elastomer and an elastic resin layer.

[0027] Preferably, the elastic pad is an office chair pad or a car seat pad, wherein the office chair pad comprises a seat cushion body and a backrest body each having different elastic support forces; and the car seat pad comprises a headrest part, a back cushion part, and a seat cushion part each having different elastic support forces.

[0028] In some embodiments, the seat cushion body comprises a comfort zone and a support zone arranged from top to bottom, the cell size of the lattice structure formed by the comfort zone and the support zone is the same, and the cell rod diameter of the lattice structure formed from top to bottom gradually decreases.

[0029] In some embodiments, the back body comprises a waist support body and a back support body, wherein the waist support body and the back support body are integrally arranged in an up-down direction and form a whole back cushion or form a left back and a right back in left-right symmetry, the unit cell size of the formed cell structure of the back cushion is the same, and the rod diameter of the formed cell structure gradually decreases from back to front; the left back comprises a support area in the middle, a comfort area on both sides of the support area, and the unit cell size of the cell structure gradually increases and the rod diameter of the cell structure gradually decreases from the middle to both sides.

[0030] Further, the office chair cushion further comprises a headrest cushion formed above the back cushion, the headrest cushion comprises a support area in the middle, a comfort area on both sides of the support area, and the unit cell size of the cell structure gradually increases and / or the rod diameter of the cell structure gradually decreases from the middle to both sides.

[0031] In some embodiments, the headrest part comprises a support layer and a comfort layer integrally formed from back to front, wherein the unit cell size of the cell structure formed by the comfort layer is smaller than the unit cell size of the cell structure formed by the support layer, and the porosity of the comfort layer is greater than the porosity of the support layer.

[0032] In some embodiments, the back cushion part comprises a waist support area and a back support area arranged in an up-down direction, the unit cell size of the cell structure of the back support area and the waist support area is the same, and the rod diameter of the cell structure formed by the back support area and the waist support area is different from back to front.

[0033] In some embodiments, the seat cushion part sequentially forms a rear support body, a middle support body, and a front support body along the length direction of the seat cushion part, wherein the thickness gradually increases from back to front, and the porosity of the rear support body, the middle support body, and the front support body gradually increases.

[0034] Preferably, in the side view projection formed by the end face in the length direction, the front support body and the rear support body are respectively located at the left and right ends, wherein the right side contour edge of the rear support body is continuously bent inward and outward from top to bottom; and / or, the left side contour edge of the front support body is rounded; and / or, the upper side contour edge and the lower side contour edge of the middle support body are symmetrically arranged about the middle part, and the upper side contour edge and the lower side contour edge respectively extend linearly and obliquely from left to right.

[0035] Preferably, the seat cushion part comprises a front support body, a middle support body and a rear support body formed in sequence along the length direction of the seat cushion part, wherein the thickness of the rear support body, the middle support body and the front support body is equal; or / and, the rear support body, the middle support body and the front support body are each divided into multiple support layers from the thickness direction, and the cell rod diameter of the lattice structure formed by each support layer gradually decreases from bottom to top; or / and, the porosity of the lattice structure gradually increases from bottom to top.

[0036] Further, the front support body is curved forward and downward, the elastic support force formed by the rear support body is greater than the elastic support force formed by the front support body, and the elastic support force formed by the front support body is less than or equal to the elastic support force formed by the middle support body.

[0037] Preferably, the seat cushion part comprises a square inner core and a core sleeve formed around the outer periphery of the inner core, wherein the elastic resin layer is formed on the inner core or / and the core sleeve.

[0038] Further, the core sleeve comprises an upper sleeve layer, a lower sleeve layer, a front sleeve layer and a rear sleeve layer, wherein the upper sleeve layer and the lower sleeve layer are symmetrically arranged, and the front sleeve layer and the rear sleeve layer are symmetrically arranged; or / and, the porosity of the upper sleeve layer is less than or equal to the porosity of the inner core, and the porosity of the front sleeve layer is greater than or equal to the porosity of the upper sleeve layer.

[0039] Preferably, the office chair cushion or the automobile seat cushion further comprises an armrest part comprising a comfort zone and a support zone arranged from top to bottom, wherein the cell rod diameter of the lattice structure gradually decreases from bottom to top; or / and, the porosity of the lattice structure gradually increases from bottom to top; or / and, the office chair cushion or the automobile seat cushion further comprises a side support part formed on both sides of the seat cushion part, wherein the structure of the side support part is the same as that of the armrest part.

[0040] Preferably, the elastic cushion is a sofa cushion or a mattress, and the sofa cushion or the mattress each comprises a comfort zone at the upper part and a support zone at the lower part, the cell rod diameter of the lattice structure formed by the comfort zone and the support zone is different, and gradually decreases from bottom to top; or, the sofa cushion or the mattress each comprises a support zone at the middle part and a comfort zone at the upper part and the lower part of the support zone, the cell rod diameter of the lattice structure formed by the comfort zone and the support zone is different, and the cell rod diameter of the lattice structure at the middle part is greater than that of the lattice structure at the upper part or the lower part.

[0041] Thanks to the implementation of the above technical solutions, the present application has the following advantages compared with the prior art:

[0042] The present application can provide the required supporting force by the layout of different elastic supporting areas, and the formed comfortable area can provide the required soft comfort, and according to the area deformation difference, the air permeability of the lattice structure elastomer itself is maintained, and the stuffiness is avoided. BRIEF DESCRIPTION OF DRAWINGS

[0043] Figure 1 The structure schematic diagram of the lattice structure elastomer in example 1 is shown in the figure.

[0044] Figure 2 The three-dimensional structure schematic diagram of the automobile seat in example 2 is shown in the figure.

[0045] Figure 3 The structure schematic diagram of the seat cushion part in example 2 is shown in the figure. Figure 2

[0046] Figure 4 The front view schematic diagram of the seat cushion part in example 2 is shown in the figure. Figure 3

[0047] Figure 5 The front view schematic diagram (1) of the seat cushion part in example 2 is shown in the figure.

[0048] Figure 6 The front view schematic diagram (2) of the seat cushion part in example 2 is shown in the figure.

[0049] Figure 7 The front view schematic diagram (3) of the seat cushion part in example 2 is shown in the figure.

[0050] Figure 8 The front view schematic diagram (4) of the seat cushion part in example 2 is shown in the figure.

[0051] Figure 9 The top view schematic diagram of the seat cushion part in example 2 is shown in the figure. Figure 8

[0052] The three-dimensional structure schematic diagram (1) of the office chair in example 3 is shown in the figure. Figure 10

[0053] The three-dimensional structure schematic diagram (2) of the office chair in example 4 is shown in the figure. Figure 11

[0054] The three-dimensional structure schematic diagram of the bed cushion in example 5 is shown in the figure. Figure 12

[0055] The three-dimensional structure schematic diagram of the sofa cushion in example 6 is shown in the figure. Figure 13

[0056] ​​​Wherein: 1, unit cell structure; 10, lattice structure elastomer; 10a, front support; 10b, middle support; 10c, rear support; 100, inner core; 101, core cover; a, upper cover layer; b, lower cover layer; c, front cover layer; d, rear cover layer; z, support layer; z1, upper support layer; z2, middle support layer; z3, lower support layer; ①, headrest part; ②, cushion part; ③, seat cushion part; ④, side support part; 100a, support layer; 100b, comfort layer; 100c, waist support area; 100d, back support area; 100e, comfort area; 100f, support area; A, headrest cushion; B, seat cushion body; C, backrest body; 1h, comfort area; 1f, support area; 1g, waist support; 1t, back support; 1k, backrest cushion; 1L, left backrest; 1R, right backrest. DETAILED DESCRIPTION

[0057] To make the above objectives, features and advantages of the present application more obvious and easy to understand, the specific embodiments of the present application are described in detail below. In the following description, a large number of specific details are set forth in order to fully understand the present application. However, the present application can be implemented in many other ways different from those described herein, and those skilled in the art can make similar improvements without departing from the spirit of the present application, so the present application is not limited to the specific embodiments disclosed below.

[0058] Embodiment 1

[0059] The lattice structure elastomer of the present embodiment is a thermoplastic elastomer forming different elastic support areas, which are divided into at least a comfort area and a support area in an XYZ three-axis coordinate system, and the softness formed by the comfort area is greater than the softness formed by the support area.

[0060] As shown in Figure 1 , the thermoplastic elastomer 10 includes a comfort area 100e and a support area 100f layered from top to bottom, the cell size of the unit cell structure formed by the comfort area 100e and the support area 100f is the same, and the cell rod diameter of the unit cell structure formed from bottom to top gradually decreases.

[0061] Specifically, the porosity of the comfort area 100e is greater than the porosity of the support area 100f, and the porosity of the formed thermoplastic elastomer is 5% to 40%.

[0062] In this example, the thermoplastic polyurethane TPU is used as the raw material, and the lattice structure elastomer is printed by powder sintering 3D printing, and the process parameters are main temperature 100-120℃, laser power 50W, scanning speed 4000-1000mm / s, scanning interval 0.2mm, and at the same time, the pressure required for the thermoplastic elastomer 10 to be compressed to a deformation of 50% is greater than 150N.

[0063] Embodiment 2

[0064] like Figure 2 As shown, the elastic pad in this embodiment is a seat cushion installed on a car seat, which includes a headrest portion ①, a backrest portion ②, and a seat cushion portion ③.

[0065] Specifically, each part of the chair cushion includes a cell structure 1, which includes a thermoplastic elastomer 10 and an elastic resin layer.

[0066] The thermoplastic elastomer 10 is a thermoplastic elastomer, and each cell structure 1 of the cushion forms a different elastic support force.

[0067] The porosity of the thermoplastic elastomer is 10% to 30%, and it is formed by powder sintering and 3D printing.

[0068] The elastic resin layer is partially formed in the internal pores of the thermoplastic elastomer 10 and bonded to the thermoplastic elastomer 10, with the remainder formed on the outer surface of the thermoplastic elastomer 10. In this way, the pressure required for the cell structure 1 constituting each part of the cushion to be compressed to 50% of its deformation is greater than 270 N.

[0069] The elastic resin that makes up the elastic resin layer has a hardness of 50A Shore A or higher and 40D Shore A or lower, a viscosity of less than 12000 cP at 25°C, a tensile strength of 5MPa or higher, and an elongation at break of 120% or higher.

[0070] The mass of the elastic resin layer is 20% to 25% of the mass of the lattice structure elastomer. This optimizes weight reduction while improving the strength, elasticity, and impact resistance of the cell structure and ensuring sufficient elastic cushioning capacity.

[0071] Lattice-structured elastomers are fabricated using 3D printing. By adjusting parameters such as 3D printing temperature and laser energy, the sintering density and porosity of the lattice-structured elastomer can be controlled, thereby controlling the depth and quality of elastic resin penetration. Lower temperatures and laser power result in higher porosity in the printed lattice-structured elastomer, a higher content of elastic resin in the cell structure, and better compressibility of the cell structure.

[0072] In some specific implementations, the parameters used are as follows: temperature 80-140℃, laser power 30-100W, scanning rate 4000-10000mm / s, and scanning spacing 0.1-0.3mm.

[0073] In this example, the thermoplastic elastomer 10 is a thermoplastic elastomer that forms different elastic support regions. The elastic support regions are divided into at least a comfort zone and a support zone in the XYZ three-axis coordinate system. The softness formed by the comfort zone is greater than that formed by the support zone.

[0074] Specifically, the thermoplastic elastomer 10 formed by the headrest part ① comprises a support layer 100a and a comfort layer 100b which are integrally formed from back to front, wherein the cell size of the crystal cell structure formed by the comfort layer 100b is smaller than the cell size of the crystal cell structure formed by the support layer 100a, and the porosity of the comfort layer 100b is greater than the porosity of the support layer 100a. That is, the user's head first contacts the comfort layer 100b, and provides comfortable elastic support under the common elastic support formed by the support layer 100a and the comfort layer 100b.

[0075] The thermoplastic elastomer 10 formed by the cushion part ② comprises an upper waist support area 100c and a back support area 100d arranged in layers, the cell size of the crystal cell structure of the back support area 100d and the waist support area 100c is the same, and the cell rod diameter of the crystal cell structure formed by the back support area 100d and the waist support area 100c is different from back to front. That is, different elastic support is provided by the waist support area 100c and the back support area 100d. Generally, the support force formed by the back support area 100d is definitely greater than the support force formed by the waist support area 100c, but it should be noted that the back support area 100d is harder than the waist support area 100c, so as to provide a cushion that fits the curve of the waist.

[0076] In combination with Figure 3 and Figure 4 It is shown that the thermoplastic elastomer 10 formed by the seat cushion part ③ comprises a comfort area 100e and a support area 100f arranged in layers from top to bottom, the cell size of the crystal cell structure formed by the comfort area 100e and the support area 100f is the same, and the cell rod diameter of the crystal cell structure formed from bottom to top gradually decreases.

[0077] In this example, the seat cushion part ③ is provided with a side support part ④ on each side, wherein the side support part ④ is symmetrically arranged, and the thermoplastic elastomer 10 formed by the side support part ④ is the same as the seat cushion part ③.

[0078] In combination with Figure 5 It is shown that the thermoplastic elastomer 10 formed by the seat cushion part ③ comprises a front support body 10a, a middle support body 10b, and a rear support body 10c which are sequentially formed along the length direction of the seat cushion part ③.

[0079] Specifically, the thickness of the thermoplastic elastomer 10 gradually increases from back to front, and the porosity of the rear support body 10c, the middle support body 10b, and the front support body 10a gradually increases. In this way, the support force formed by different parts provides different elastic support under different forces, so as to meet the comfort needs of different groups of people, and under high strength support, the air permeability of the seat cushion is ensured, the heat dissipation performance of the seat cushion is effectively improved, and the stuffiness is relieved.

[0080] Specifically, the front support body forms an elastic resin layer, and the pressure required to compress the elastic resin layer to 50% deformation is greater than 200 N.

[0081] Meanwhile, in a side view projection of the thermoplastic elastomer 10 from the end face in the length direction, the front support body 10a and the rear support body 10c are respectively located at the left and right ends, and the left profile edge of the front support body 10a is rounded and transitions.

[0082] The upper profile edge and the lower profile edge of the middle support body 10b are symmetrically arranged about the middle, and the upper profile edge and the lower profile edge respectively extend linearly and obliquely from left to right. The comfort level formed in this way can better meet the comfort level of different people.

[0083] In combination Figure 6 As shown, the thermoplastic elastomer 10 formed by the seat cushion part ③ includes a square inner core 100 and a core sleeve 101 formed on the outer periphery of the inner core 100, and the pressure required to compress the crystal cell structure 1 to 50% deformation is greater than 270 N.

[0084] The core sleeve 101 includes an upper sleeve layer a, a lower sleeve layer b, a front sleeve layer c, and a rear sleeve layer d, wherein the upper sleeve layer a and the lower sleeve layer b are symmetrically arranged, and the front sleeve layer c and the rear sleeve layer d are symmetrically arranged.

[0085] The porosity of the upper sleeve layer a is equal to the porosity of the inner core 100, and the porosity of the front sleeve layer c is greater than the porosity of the upper sleeve layer a. Further improve the air permeability, and provide comfortable support force.

[0086] In combination Figure 7 As shown, in the thermoplastic elastomer 10 formed by the seat cushion part ③, the porosity of the upper sleeve layer a is less than the porosity of the inner core 100, and the porosity of the front sleeve layer c is equal to the porosity of the upper sleeve layer a. Further improve the air permeability, and provide comfortable support force.

[0087] In combination Figure 8 As shown, the thermoplastic elastomer 10 formed by the seat cushion part ③ includes a rear support body 10c, a middle support body 10b, and a front support body 10a formed in sequence along the length direction of the thermoplastic elastomer 10, wherein the thicknesses of the rear support body 10c, the middle support body 10b, and the front support body 10a are equal.

[0088] The rear support body 10c, the middle support body 10b, and the front support body 10a are respectively divided into multiple support layers z from the thickness direction, and the porosity of each support layer z gradually increases from bottom to top.

[0089] In combination Figure 9As shown, the support layer z is the upper, middle and lower three layers (upper support layer z1, middle support layer z2, lower support layer z3), and the diameter of the rod formed by each layer of support layer from bottom to top gradually increases.

[0090] The front support body 10a is bent forward and downward; the elastic support force formed by the rear support body 10c is greater than the elastic support force formed by the front support body 10a, and the elastic support force formed by the front support body 10a is equal to the elastic support force formed by the middle support body 10b.

[0091] After the front support body 10a forms the elastic resin layer, the pressure required when being compressed to 50% deformation is greater than 200N.

[0092] In addition, the cell modeling of the lattice cell structure constituting the thermoplastic elastomer 10 is not particularly limited.

[0093] At the same time, the headrest part ①, the cushion part ②, the seat cushion part ③ and the side support part ④ have the same molding process, and the molding process of the seat cushion part ③ is taken as an example, which includes the following steps:

[0094] 1) Using thermoplastic polyurethane (TPU) as raw material, 3D printing lattice structure elastomer by powder sintering, the process parameters are main temperature 100-120℃, laser power 50W, scanning speed 4000-1000mm / s, scanning interval 0.2mm.

[0095] 2) Mix and disperse 94 parts by mass of commercially available polyurethane resin solution with a mass concentration of 45% and 6 parts by mass of isocyanate curing agent by using a high-speed stirrer to obtain an impregnation treatment solution, wherein the hardness of the polyurethane resin is 60A, the viscosity at 25℃ is 8000cP, the tensile strength is 10MPa, and the elongation at break is 200%.

[0096] 3) Soak the printed lattice structure elastomer in the impregnation treatment solution prepared in step 2) for 8 minutes, dry after taking out, and then put it into a vacuum oven at 80±2℃ for 2.5h to obtain a composite material sample.

[0097] The sintering density and porosity of the lattice structure elastomer obtained at different scanning speeds, and the weight of the lattice structure elastomer before and after treatment with polyurethane resin, and the pressure when the compression deformation is 50% (the average value of the front, middle and rear support bodies) are shown in Table 1 as follows:

[0098] Table 1

[0099]

[0100] As can be seen from Table 1 above, by controlling the process parameters of 3D printing, the sintering density and porosity of the crystal lattice structure elastomer can be adjusted. The greater the porosity, the more the content of polyurethane resin in the crystal cell structure, and the more the compression resistance of the composite elastomer material is improved.

[0101] Embodiment 3

[0102] As Figure 10 shown, the elastic pad of the present embodiment is a chair pad arranged on an office chair, which comprises a seat cushion body B and a backrest body C, both having different elastic support forces.

[0103] Both the seat cushion body B and the backrest body C comprise a crystal cell structure 1, which comprises a thermoplastic elastomer 10 and an elastic resin layer.

[0104] The thermoplastic elastomer 10 of the seat cushion body B comprises a comfort zone 1h and a support zone 1f arranged from top to bottom, the cell sizes of the crystal cell structures formed by the comfort zone 1h and the support zone 1f are the same, and the cell rod diameters of the crystal cell structures formed from bottom to top gradually decrease.

[0105] The thermoplastic elastomer 10 of the backrest body C comprises a waist support body 1g and a back support body 1t, wherein the waist support body 1g and the back support body 1t are integrally arranged from top to bottom and form a whole backrest pad 1k.

[0106] The cell sizes of the crystal cell structure of the backrest pad 1k are the same, and the cell rod diameters of the crystal cell structure formed from back to front gradually decrease.

[0107] The office chair further comprises a headrest pad A formed on the backrest pad 1k, the thermoplastic elastomer 10 of the headrest pad A comprises a support zone 1f in the middle and comfort zones 1h on both sides of the support zone 1f, and the cell sizes and / or the cell rod diameters of the crystal cell structures gradually increase and / or decrease from the middle to the sides.

[0108] Meanwhile, the forming processes of the headrest pad A, the seat cushion body B and the backrest body C are the same, and the forming process of the seat cushion body ② is taken as an example, which comprises the following steps:

[0109] 1) taking thermoplastic polyurethane (TPU) as raw material, a crystal lattice structure elastomer is 3D printed by powder sintering, and the process parameters are main temperature 100-120℃, laser power 80W, scanning speed 8000mm / s and scanning interval 0.2mm;

[0110] 2) Mix 98 parts by weight of a commercially available acrylic resin solution with a mass concentration of approximately 55% and 2 parts by weight of a curing agent 4,4'-methylenebis(2-methylcyclohexylamine) evenly with a high-speed stirrer to obtain an impregnation treatment solution. The acrylic resin has a hardness of 70A, a viscosity of 10000cP at 25°C, a tensile strength of 12MPa, and an elongation at break of 180%.

[0111] 3) Immerse the printed TPU lattice structure elastomer in the impregnation solution for 10 minutes, remove it and spin dry, then place it in an 80℃ vacuum oven to cure for 5 hours to obtain a cellular structure sample.

[0112] 4) Place the cured sample back into the impregnation solution, soak for 10 minutes, spin dry, and cure.

[0113] In other words, two elastic resin layers are formed on the surface of the lattice structure elastomer in the resulting cell structure 1. Simultaneously, the weight of cell structure 1 is increased from 865g to 1068g, and the pressure at 50% compressive deformation increases from 270.1N to 577.3N. The density of the prepared cell structure is 1.003g / cm³. 3 .

[0114] Example 4

[0115] like Figure 11 As shown, the elastic cushion in this embodiment is a cushion installed on an office chair (without a headrest). The cushion includes a seat body B and a backrest body C, each with different elastic support forces.

[0116] Both the seat cushion body B and the backrest body C include a cell structure 1, which includes a thermoplastic elastomer 10 and an elastic resin layer.

[0117] Specifically, the thermoplastic elastomer 10 of the seat cushion body B includes a comfort zone 1h and a support zone 1f arranged from top to bottom. The cell size of the crystal structure formed by the comfort zone 1h and the support zone 1f is the same, and the cell rod diameter of the crystal structure formed from bottom to top gradually decreases.

[0118] The thermoplastic elastomer 10 of the backrest body C includes a lumbar support 1g and a back support 1t, wherein the lumbar support 1g and the back support 1t are integrally set up and form a left backrest 1L and a right backrest 1R that are symmetrical from left to right.

[0119] The left backrest 1L includes a support area 1f in the middle and comfort areas 1h on both sides of the support area 1f. The cell size of the cell structure gradually increases and the cell rod diameter gradually decreases from the middle to the sides.

[0120] Meanwhile, the molding processes for seat cushion B and backrest C are the same. Taking seat cushion ② as an example, the molding process for seat cushion ② includes the following steps:

[0121] 1) Using thermoplastic polyurethane (TPU) as raw material, a lattice structure elastomer is 3D printed by powder sintering. The process parameters are: main temperature 100-120℃, laser power 80W, scanning speed 8000mm / s, and scanning spacing 0.2mm.

[0122] 2) Mix 98 parts by weight of a commercially available acrylic resin solution with a mass concentration of approximately 55% and 2 parts by weight of a curing agent 4,4'-methylenebis(2-methylcyclohexylamine) evenly with a high-speed stirrer to obtain an impregnation treatment solution. The acrylic resin has a hardness of 70A, a viscosity of 10000cP at 25°C, a tensile strength of 12MPa, and an elongation at break of 180%.

[0123] 3) Immerse the printed TPU lattice structure elastomer in the impregnation solution for 10 minutes, remove it and spin dry, then place it in an 80℃ vacuum oven to cure for 5 hours to obtain a cellular structure sample.

[0124] 4) Place the cured sample back into the impregnation solution, soak for 10 minutes, spin dry, and cure.

[0125] In other words, during the molding process of cell structure 1, three elastic resin layers are formed on the surface of the lattice structure elastomer in the formed cell structure 1. Simultaneously, the weight of cell structure 1 is increased from 924g to 1136g, and the pressure at 50% material compression deformation increases from 290.1N to 650.5N. The density of the prepared cell structure is 1.099g / cm³. 3 .

[0126] Example 5

[0127] like Figure 12 As shown, the elastic pad in this embodiment is a mattress, which includes a cell structure 1, and the cell structure 1 includes a thermoplastic elastomer 10 and an elastic resin layer.

[0128] Specifically, the thermoplastic elastomer 10 has a comfort zone 1h and a support zone 1f with different elastic support forces.

[0129] The comfort zone 1h is located above the support zone 1f, and the cell shapes of the unit cell structures formed by the comfort zone 1h and the support zone 1f are different. At the same time, the cell rod diameter gradually decreases from bottom to top.

[0130] Meanwhile, the mattress forming process includes the following steps:

[0131] 1) using thermoplastic polyurethane (TPU) as raw material, a lattice structure elastomer is printed by powder sintering 3D printing, and the process parameters are main temperature 100-120℃, laser power 80W, scanning speed 8000mm / s, and scanning interval 0.2mm;

[0132] 2) 98 parts by mass of a commercially available acrylic resin solution with a mass concentration of about 55%, 2 parts by mass of a curing agent 4,4'-methylenebis(2-methylcyclohexylamine), and 2 parts by mass of a curing agent 4,4'-methylenebis(2-methylcyclohexylamine) are uniformly dispersed and mixed by a high-speed stirrer to obtain an impregnation treatment solution, wherein the hardness of the acrylic resin is 70A, the viscosity at 25℃ is 10000cP, the tensile strength is 12MPa, and the elongation at break is 180%;

[0133] 3) the printed TPU lattice structure elastomer is soaked in the impregnation treatment solution for 10min, then taken out and dried, and then placed in a vacuum oven at 80℃ for 5h to obtain a unit cell structure sample;

[0134] 4) the cured sample is placed in the impregnation treatment solution again, soaked for 10min, dried, and cured.

[0135] That is, during the molding process of the unit cell structure 1, three layers of elastic resin layers are formed on the surface of the lattice structure elastomer in the unit cell structure 1, and the weight of the unit cell structure 1 is increased from 9200g before treatment to 11224g, and the pressure when the material compression deformation is 50% is increased from 450.2N before treatment to 990.2N. The density of the prepared unit cell structure is 1.012g / cm 3 .

[0136] Example 6

[0137] As shown in Figure 13 , the elastic pad of the present embodiment is a sofa pad, which comprises a unit cell structure 1, and the unit cell structure 1 comprises a thermoplastic elastomer 10 and an elastic resin layer.

[0138] Specifically, the thermoplastic elastomer 10 has a comfort zone 1h with different elastic support force and a support zone 1f.

[0139] In this example, the support zone 1f is located in the middle, and the comfort zone 1h is located in the upper and lower parts of the support zone 1f, wherein the cell modeling of the unit cell structure formed by the comfort zone 1h and the support zone 1f is different, and the cell rod diameter of the unit cell structure in the middle is greater than that of the unit cell structure in the upper or lower part.

[0140] At the same time, the sofa pad molding process comprises the following steps:

[0141] 1) using thermoplastic polyurethane (TPU) as raw material, a lattice structure elastomer is printed by powder sintering forming 3D printing, and the process parameters are main temperature 100-120 DEG C, laser power 80W, scanning speed 8000mm / s, and scanning interval 0.2mm;

[0142] 2) 98 parts by mass of a commercially available acrylic resin solution with a mass concentration of about 55%, 2 parts by mass of a curing agent 4,4'-methylenebis(2-methylcyclohexylamine), and a high-speed stirrer are mixed and uniformly dispersed to obtain an impregnation treatment solution, wherein the hardness of the acrylic resin is 70A, the viscosity at 25 DEG C is 10000cP, the tensile strength is 12MPa, and the elongation at break is 180%;

[0143] 3) the printed TPU lattice structure elastomer is soaked in the impregnation treatment solution for 10 minutes, then taken out and dried, and then placed in a 80 DEG C vacuum oven for 5 hours to obtain a unit cell structure sample;

[0144] 4) the cured sample is placed in the impregnation treatment solution again, soaked for 10 minutes, dried, and cured.

[0145] That is, in the forming process of the unit cell structure 1, three layers of elastic resin layers are formed on the surface of the thermoplastic elastomer 10 in the formed unit cell structure 1, and the weight of the unit cell structure 1 is increased from 4600g before treatment to 5300g, and the pressure when the material compression deformation is 50% is increased from 350.5N before treatment to 656.3N. The density of the prepared unit cell structure is 1.012g / cm 3 .

[0146] Therefore, the present application has the following advantages:

[0147] 1. The present application can provide the required support force by different elastic support area layout, and the formed comfortable area can provide soft and comfortable needs, and the porosity design ensures the air permeability of the present application, and the stuffiness is relieved;

[0148] 2. The present application is composed of lattice structure elastomer and elastic resin coating, so that the elastic resin penetrates into the internal pores of the lattice structure elastomer and is tightly combined with the lattice structure elastomer, unexpectedly, without affecting the advantage performance of the lattice structure elastomer, the compression resistance of the material is significantly improved, and at the same time, the volume of the material is unchanged, and the weight is only slightly increased. Compared with the lattice structure elastomer without composite elastic resin coating, the volume of the unit cell structure of the present application is significantly smaller and the weight is significantly lighter when the same compression resistance is achieved; the compression resistance of the unit cell structure of the present application is significantly higher when the weight is the same.

[0149] 3. The preparation process of the unit cell structure of the application adopts 3D printing to prepare the lattice structure elastomer, and adopts coating treatment and curing process. On the one hand, by adjusting the 3D printing temperature and laser power and other parameters, the sintering density and porosity of the lattice structure elastomer can be controlled, and then the depth and quality of the elastic resin penetration can be controlled, and finally the degree of improvement of the compression performance of the unit cell structure can be controlled, so that unit cell structures with various performances can be flexibly prepared to meet the individual needs in various application scenarios. On the other hand, by adopting the coating treatment and curing process, the combination between the lattice structure elastomer and the elastic resin coating is more sufficient and close, which helps to improve the strength and service life of the unit cell structure.

[0150] The endpoints of the ranges and any values disclosed herein are not limited to the precise values recited as the exact dimensions are dependent upon a number of factors which can vary with the use of the compositions and methods disclosed herein. The endpoints of the ranges and any values disclosed herein should be understood to be open-ended ranges. The ranges disclosed herein are also intended to cover any and all sub-ranges of the ranges, unless otherwise indicated. For example, a stated range of 2% to 10% should be considered to include any and all sub-ranges beginning with either 2% or 10% and ending with the opposite number, i.e., 2% to 8%, 3% to 10%, and so forth.

Claims

1. A lattice-structured elastomer, characterized in that: The lattice-structured elastomer is a thermoplastic elastomer that forms different elastic support regions. The elastic support regions are divided into at least a comfort region and a support region in the XYZ triaxial coordinate system, with the comfort region exhibiting greater softness than the support region. An elastic resin layer is formed on the thermoplastic elastomer, which is formed at least within the internal pores of the thermoplastic elastomer and bonded to it. The thermoplastic elastomer and the elastic resin layer constitute a unit cell structure. The elastic resin layer is also formed on the outer surface of the lattice-structured elastomer. The unit cell structure requires a pressure greater than 270 N to be compressed to 50% of its deformation. The porosity of the thermoplastic elastomer is 5%–40%.

2. The lattice structure elastomer according to claim 1, characterized in that: The elastic resin constituting the elastic resin layer has a hardness of 50A Shore A or higher and 40D Shore A or lower, a viscosity of less than 12000 cP at 25°C, a tensile strength of 5MPa or higher, and an elongation at break of 120% or higher.

3. The lattice structure elastomer according to claim 1, characterized in that: The mass of the elastic resin layer is 10% to 50% of the mass of the lattice structure elastomer.

4. The lattice structure elastomer according to claim 1, characterized in that: The density of the thermoplastic elastomer is 0.7-1.1 g / cm³. 3 .

5. The lattice structure elastomer according to any one of claims 1 to 4, characterized in that: The cell structure is formed by coating the lattice structure elastomer with a treatment liquid containing the elastic resin or its raw materials and a curing agent.

6. The lattice structure elastomer according to claim 5, characterized in that: The coating process involves spraying, dipping, or electroplating. During the coating process, the treatment solution penetrates into the internal pores of the lattice structure elastomer.

7. The lattice structure elastomer according to claim 6, characterized in that: The treatment liquid contains 30-60% elastic resin by mass and 1%-10% curing agent by mass. The heat curing is carried out at a temperature of 80-100℃. The coating treatment and heat curing are performed once, or after one treatment, they are repeated 1-3 times.

8. An elastic pad made of a lattice structure elastomer, characterized in that: The elastic pad comprises a lattice structure elastomer as described in any one of claims 1 to 7 and the elastic resin layer.

9. The elastic pad made of a lattice structure elastomer according to claim 8, characterized in that: The elastic pad is an office chair pad or a car seat pad, wherein the office chair pad includes a seat cushion and a backrest, each with different elastic support; and the car seat pad includes a headrest, a backrest, and a seat cushion, each with different elastic support.

10. The elastic pad made of a lattice structure elastomer according to claim 9, characterized in that: The seat cushion includes a comfort zone and a support zone arranged from top to bottom. The cell size of the crystalline structure formed by the comfort zone and the support zone is the same, and the cell diameter of the crystalline structure formed from bottom to top gradually decreases.

11. The elastic pad made of a lattice structure elastomer according to claim 9, characterized in that: The backrest body includes a lumbar support and a back support, wherein the lumbar support and the back support are integrally formed to form a single backrest cushion or to form a symmetrical left backrest and a right backrest. The cell size of the cell structure formed by the backrest cushion is the same, and the cell rod diameter gradually decreases from back to front. The left backrest includes a support area in the middle and comfort areas on both sides of the support area, and the cell size and cell rod diameter gradually increase from the middle to both sides.

12. The elastic pad made of a lattice structure elastomer according to claim 11, characterized in that: The office chair cushion also includes a headrest cushion formed above the backrest cushion. The headrest cushion includes a support area in the middle and comfort areas on both sides of the support area. The cell size of the cell structure gradually increases and / or the cell rod diameter gradually decreases from the middle to the sides.

13. The elastic pad made of a lattice structure elastomer according to claim 9, characterized in that: The headrest includes a support layer and a comfort layer integrally formed from back to front, wherein the cell size of the unit structure formed by the comfort layer is smaller than the cell size of the unit structure formed by the support layer, and the porosity of the comfort layer is greater than the porosity of the support layer.

14. The elastic pad made of a lattice structure elastomer according to claim 9, characterized in that: The cushion includes a waist support area and a back support area arranged vertically. The cell size of the unit cell structure of the back support area and the waist support area is the same, and the cell rod diameter of the unit cell structure formed from back to front of the back support area and the waist support area is different.

15. The elastic pad made of a lattice structure elastomer according to claim 9, characterized in that: The seat cushion is formed sequentially along its length by a rear support, a middle support, and a front support, with the thickness gradually increasing from back to front, and the porosity of the rear support, the middle support, and the front support gradually increasing.

16. The elastic pad made of a lattice structure elastomer according to claim 15, characterized in that: In the side view projection formed by the end face of the seat cushion portion along its length direction, the front support and the rear support are located at the left and right ends respectively, wherein the right contour edge of the rear support is continuously bent inward and outward from top to bottom.

17. The elastic pad made of a lattice structure elastomer according to claim 16, characterized in that: The left side of the front support has a rounded corner transition.

18. The elastic pad made of a lattice structure elastomer according to claim 16, characterized in that: The upper and lower contour edges of the central support are symmetrically arranged about the center, and the upper and lower contour edges extend in a straight line from left to right.

19. The elastic pad made of a lattice structure elastomer according to claim 9, characterized in that: The seat cushion includes a front support, a middle support, and a rear support, which are formed sequentially along its length, wherein the thickness of the rear support, the middle support, and the front support is equal.

20. The elastic pad made of a lattice structure elastomer according to claim 19, characterized in that: The rear support, middle support, and front support are each divided into multiple support layers in the thickness direction, and the cell rod diameter of the crystal structure formed by each support layer gradually decreases from bottom to top.

21. The elastic pad made of a lattice structure elastomer according to claim 19, characterized in that: The porosity of the lattice structure formed from bottom to top gradually increases.

22. The elastic pad made of a lattice structure elastomer according to claim 19, characterized in that: The front support body bends forward and downward; the elastic support force formed by the rear support body is greater than the elastic support force formed by the front support body, and the elastic support force formed by the front support body is less than or equal to the elastic support force formed by the middle support body.

23. The elastic pad made of a lattice structure elastomer according to claim 9, characterized in that: The cushion portion includes a square inner core and a core sleeve formed on the outer periphery of the inner core, wherein the elastic resin layer is formed on the inner core and / or the core sleeve.

24. The elastic pad made of a lattice structure elastomer according to claim 23, characterized in that: The core sleeve includes an upper sleeve layer, a lower sleeve layer, a front sleeve layer, and a rear sleeve layer, wherein the upper sleeve layer and the lower sleeve layer are symmetrically arranged, and the front sleeve layer and the rear sleeve layer are symmetrically arranged.

25. The elastic pad made of a lattice structure elastomer according to claim 24, characterized in that: The porosity of the upper sleeve layer is less than or equal to the porosity of the inner core, and the porosity of the front sleeve layer is greater than or equal to the porosity of the upper sleeve layer.

26. The elastic pad made of a lattice structure elastomer according to claim 9, characterized in that: The office chair cushion or car seat cushion also includes an armrest, which includes a comfort zone and a support zone arranged from top to bottom, wherein the cell rod diameter of the crystalline structure formed from bottom to top gradually decreases.

27. The elastic pad made of a lattice structure elastomer according to claim 26, characterized in that: The porosity of the lattice structure formed from bottom to top gradually increases.

28. The elastic pad made of a lattice structure elastomer according to claim 27, characterized in that: The office chair cushion or car seat cushion also includes side support portions formed on both sides of the seat cushion portion, wherein the structure of the side support portion is the same as the structure of the armrest portion.

29. The elastic pad made of a lattice structure elastomer according to claim 9, characterized in that: The elastic pad is a sofa cushion or a mattress, and the sofa cushion or mattress includes a comfort zone at the top and a support zone at the bottom. The cell shapes of the crystal structures formed by the comfort zone and the support zone are different, and the cell rod diameter gradually decreases from bottom to top.

30. The elastic pad made of a lattice structure elastomer according to claim 29, characterized in that: The sofa cushion or mattress includes a support area in the middle and comfort areas above and below the support area. The cell shapes of the unit cell structures formed by the comfort area and the support area are different, and the cell rod diameter of the unit cell structure in the middle is larger than that of the unit cell structure in the upper or lower part.

Images