High-elastic three-dimensional net-shaped three-dimensional supporting structure and high-elastic seat

Abstract

The invention relates to the field of buffering materials, and particularly discloses a high-elastic seat with a high-elastic three-dimensional net-shaped three-dimensional supporting structure. The high-elastic three-dimensional net-shaped three-dimensional supporting structure is prepared from the following raw materials in parts by weight through granulation, extrusion, molding and irradiation: 10-90 parts of POE (Polyolefin Elastomer) with the melting point of less than or equal to 90 DEG C, 10-90 parts of elastomer containing an ethylenic bond type polymerizable unit, 0.1-5 parts of a crosslinking aid and 0.01-0.5 part of an antioxidant. The high-elastic three-dimensional net-shaped three-dimensional supporting structure can be used for manufacturing a lining layer of a seat, and has the advantages of being small in thickness, light in weight, good in rebound resilience and high in bearing force.

Description

Technical Field

[0001] The present application relates to the technical field of cushioning materials, and more specifically, to a high-elastic three-dimensional mesh support structure and a high-elastic seat. Background Art

[0002] At present, mesh structure materials are gradually being widely used as cushioning materials used in furniture, beds and other bedding, and seats for vehicles such as trams and cars. The three-dimensional mesh structure is a molded product with an elastic structure. It uses thermoplastic plastic as a raw material to make long fibers, which are then curled into a three-dimensional mesh structure. The material can be reprocessed and recycled. The structure contains a large number of gaps and has good air permeability and lightweight properties. It can be used as a support pad to replace traditional thermosetting polyurethane foam cotton, which can not only reduce the environmental burden, but also give the product better comfort.

[0003] The support and durability of the three-dimensional mesh structure are closely related to the materials used. The three-dimensional mesh structure can use various soft plastics or thermoplastic elastomers, including polyethylene, ethylene vinyl acetate copolymer, polyolefin elastomer, thermoplastic polyurethane elastomer, thermoplastic polyester elastomer or thermoplastic polyamide elastomer. Considering the comfort of the material, thermoplastic elastomer is better than soft plastic. Thermoplastic polyester elastomer is a crystalline material. When a low-hardness thermoplastic polyester elastomer is used as the material of the three-dimensional mesh structure, the three-dimensional mesh structure has low crystallinity and good softness, but the support is small. To achieve the required support, more materials are required, resulting in a thicker and heavier finished three-dimensional mesh structure. When using high-hardness thermoplastic polyester elastomer as the material of the three-dimensional network structure, although the required bearing force can be achieved at a lower density and the three-dimensional network structure product is lighter, the high-hardness polyester elastomer also has a high degree of crystallinity, resulting in the three-dimensional network structure having a poor touch, strong rigidity, high hardness, and poor resilience, which is not suitable for use as a cushion. Summary of the invention

[0004] In order to improve the resilience and supporting force of the three-dimensional mesh material and make the finished product lightweight, the present application provides a high-elastic three-dimensional mesh support structure and a high-elastic seat.

[0005] In the first aspect, the present application provides a highly elastic three-dimensional mesh support structure, which adopts the following technical solution: a highly elastic three-dimensional mesh support structure, which is made by granulating, extruding, molding and irradiating the following raw materials in parts by weight: 10-90 parts of POE elastomer with a melting point ≤90°C, 10-90 parts of an elastomer containing olefinic polymerizable units, 0.1-5 parts of a cross-linking aid, and 0.01-0.5 parts of an antioxidant.

[0006] By adopting the above technical scheme, POE elastomer with a melting point of ≤90°C and elastomer containing olefinic polymerizable units are used as the main materials of the three-dimensional network support structure. After radiation, they are cross-linked with each other, making the support structure relatively soft, with large bearing force, good compression deformation durability and resilience. The filler is mainly used to improve the mechanical strength and process performance.

[0007] Optionally, the POE elastomer with a melting point of ≤90° C. is selected from one or more of ethylene-butene copolymer and ethylene-octene copolymer.

[0008] By adopting the above technical scheme, ethylene-butene copolymer and ethylene-octene copolymer have excellent low-temperature flexibility, high elasticity, aging resistance, transparent appearance, and good mechanical properties. After radiation cross-linking, the heat resistance temperature is improved, the permanent deformation is reduced, and the mechanical strength such as tensile strength and tear strength is greatly improved. The prepared support structure has strong resilience and softness. The composite material formed by radiation cross-linking with an elastomer containing olefinic polymerizable units has good resilience, high softness, and strong supporting force.

[0009] Optionally, the elastomer containing ethylenic polymerizable units is selected from at least one of EPDM, polybutadiene, polyisoprene, styrene-butadiene copolymer, acrylonitrile-butadiene copolymer, methyl methacrylate-butadiene copolymer, acrylonitrile-isoprene copolymer, methyl methacrylate-isoprene copolymer, isoprene-styrene copolymer, chloroprene rubber, natural rubber, and butyl rubber.

[0010] By adopting the above technical scheme, the EPDM molecular chain has a saturated structure, the molecular chain is flexible and elastic, has excellent properties such as heat resistance, aging resistance, chemical corrosion resistance, etc., has a small relative density, light weight, excellent processing performance, and high yield strength, tensile strength and elastic modulus, so that the high-elastic three-dimensional mesh support structure has good resilience and strong supporting force.

[0011] Optionally, the highly elastic three-dimensional mesh support structure is made by granulating, extruding, molding and irradiating the following raw materials in parts by weight: 30-70 parts of ethylene-octene copolymer, 30-70 parts of EPDM, 0.1-5 parts of cross-linking aid, 0.01-0.5 parts of antioxidant, 1-50 parts of filler and 1-30 parts of flame retardant.

[0012] By adopting the above technical scheme, the EPDM molecular chain is a saturated structure, and there is no unsaturated bond in the ethylene-octene copolymer molecular chain. After the ethylene-octene copolymer and EPDM are melt-blended, they are cross-linked by radiation, and the ethylene-octene copolymer is recrystallized to form crystalline segments, and physical cross-linking points are formed in the ethylene-octene copolymer / EPDM, thereby improving the hardness and tensile strength of the three-dimensional support structure. Under the action of the cross-linking auxiliary agent, the number of chemical cross-linking points in the support structure is improved, and the supporting force and tensile strength of the product's high-elastic three-dimensional mesh support structure are improved, so that the supporting structure has high supporting force, good compression deformation durability, and excellent resilience while being lightweight.

[0013] Optionally, the highly elastic three-dimensional mesh support structure is made by granulating, extruding, molding and irradiating the following raw materials in parts by weight: 30-70 parts of ethylene-butene copolymer, 30-70 parts of EPDM, 1.5-3.5 parts of cross-linking aid, 0.1-0.3 parts of antioxidant, 1-50 parts of filler and 1-30 parts of flame retardant.

[0014] By adopting the above technical scheme, the ethylene-butene copolymer has high tensile strength and tear resistance, good elasticity and wear resistance, and after radiation cross-linking with EPDM, it can form a three-dimensional mesh support structure with good tensile resistance and good resilience.

[0015] Optionally, the cross-linking aid is selected from at least one of triallyl isocyanurate, trimethylolpropane trimethacrylate and dicumyl peroxide.

[0016] Optionally, the antioxidant comprises a hindered phenol antioxidant and a phosphite antioxidant in a mass ratio of 2-5:1.

[0017] By adopting the above technical solution, hindered phenol antioxidants and phosphite antioxidants are compounded as antioxidants, the oxidation resistance of the high-elastic three-dimensional network support structure can be improved, its aging rate can be reduced, and the service life can be extended.

[0018] Optionally, the hindered phenol antioxidant is selected from at least one of pentaerythritol tetrakis[β-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate (antioxidant 1010), β-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate (antioxidant 1076) and 2,2'-thiobis[3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate] (antioxidant SKY-1035).

[0019] Optionally, the phosphite antioxidant is selected from at least one of tris(2,4-di-tert-butyl)phenyl phosphite (antioxidant PKY-168) and bis(2,4-di-tert-butylphenyl) (antioxidant JC-242).

[0020] Optionally, the filler is selected from at least one of talc powder, calcium carbonate, mica powder and montmorillonite powder.

[0021] Optionally, the flame retardant is selected from at least one of red phosphorus, decabromodiphenylethane, ammonium polyphosphate, melamine, aluminum hydroxide, magnesium hydroxide, diammonium phosphate, and ammonium chloride.

[0022] By adopting the above technical solution, red phosphorus, decabromodiphenylethane, ammonium polyphosphate, melamine, aluminum hydroxide, magnesium hydroxide and the like are added as flame retardants to the high-elastic three-dimensional mesh support structure, which can make it have a flame retardant effect and improve its safety in use.

[0023] Optionally, the density of the highly elastic three-dimensional mesh support structure is 20-200 kg / m 3 .

[0024] By adopting the above technical solution, the high-elastic three-dimensional mesh support structure with the above density has a stable support effect, and at the same time has good ventilation effect and good softness.

[0025] Optionally, the thickness of the highly elastic three-dimensional mesh support structure is ≤1 cm.

[0026] By adopting the above technical solution, the high-elastic three-dimensional mesh support structure of the above thickness can provide strong supporting force, and the thickness is thin, meeting the lightweight requirements, and has good ventilation and air permeability, can quickly cool down, and improve the comfort of drivers and passengers.

[0027] Optionally, the irradiation dose is 1-100 kGy.

[0028] By adopting the above technical solution, under this irradiation dose, the probability of the rays interacting with the molecules of the irradiated material per unit time increases, the density of free radicals required for cross-linking increases, and the natural cross-linking reaction is also fast.

[0029] Optionally, the molding is performed by cooling and curing, and the water temperature used for cooling and curing is 10-45°C.

[0030] By adopting the above technical scheme, the spun fibers are solidified under cooling, and the fibers do not have time to crystallize. Due to the low degree of crystallinity or the small crystal grains, the fiber appearance is transparent or translucent. In addition, the low degree of crystallinity or the small crystal grains make the fiber relatively soft. Therefore, the highly elastic three-dimensional mesh support structure is more comfortable and has good supporting force. If cooling and solidification are not performed, the fiber has a high degree of crystallinity or large crystal grains, the fiber appears opaque, and has greater rigidity, high hardness, and poor resilience.

[0031] In a second aspect, the present application provides a high-elastic seat, which adopts the following technical solution: A high-elastic seat comprises an inner lining layer made by cutting and bonding a high-elastic three-dimensional mesh support structure.

[0032] By adopting the above technical solution, the high-elastic three-dimensional mesh support structure is cut according to the shape of the seat, and then bonded to form the lining of the seat. Therefore, the shape of the lining layer can be spliced ​​and changed according to the shape of the seat, so that when the driver and passengers are on the seat, the sensory hardness of different parts of the body is closer, which improves the riding comfort of the seat. In addition, the lining made of the high-elastic three-dimensional mesh support structure has a large porosity, which can improve the ventilation efficiency of the seat and can achieve cooling of the seat cushion or backrest area in a short time. The inner lining layer is prepared by hot pressing, that is, the inner lining layer is hot-pressed by a mold to form the required seat shape, and the excess material of the inner lining layer that does not conform to the shape of the seat is pressed into the inner lining layer, which affects the resilience of the inner lining layer and there will be processing problems. When the inner lining layer is directly cut into the required shape of the seat by cutting, it will cause waste of raw materials. In addition, since the thickness of the high-elastic three-dimensional mesh support structure is relatively thin, the edge of the inner lining layer does not need to be cut or trimmed by the high-elastic three-dimensional mesh support structure after splicing, which does not affect the coating of the surface layer.

[0033] In summary, this application has the following beneficial effects: 1. Since the present application adopts POE elastomer with a melting point less than or equal to 90°C and elastomer containing olefinic polymerizable units as the main materials, and adds a cross-linking aid, the two are cross-linked under the action of radiation to obtain a highly elastic three-dimensional mesh support structure with good resilience, high softness and strong supporting force, and can also meet the requirements of lightweight, high compression resistance and comfort.

[0034] 2. In the present application, the thickness of the three-dimensional support structure is preferably less than or equal to 1 cm, which reduces the thickness, meets the lightweight performance, and ensures the resilience. The thinner high-elastic three-dimensional mesh three-dimensional support structure can realize the combination of multiple high-elastic three-dimensional mesh support structures to form an irregular ergonomic three-dimensional mesh structure, which can be spliced ​​and combined into the required seat lining, which can save costs and does not require mold making, and will not waste raw materials due to large-area material removal.

[0035] 3. In the present application, it is preferred to use a method of cutting and bonding according to the shape of the seat to line the seat with a high-elastic three-dimensional mesh support structure, which can keep the elasticity of various parts of the seat consistent and improve the comfort of the seat. DETAILED DESCRIPTION Example

[0036] Example 1: A highly elastic three-dimensional mesh support structure is made of the raw materials in Table 1 by granulation, extrusion, molding and radiation, wherein the POE elastomer with a melting point of ≤90°C is an ethylene-octene copolymer, model 8407, and a density of 0.87 g / cm 3, the melt index (190°C, 2.16kg) is 30g / 10min, the elastomer containing ethylenic polymerizable monomer is EPDM, the antioxidant is a hindered phenol antioxidant 1010 and a phosphite antioxidant PEP-36 with a mass ratio of 5:1, and the cross-linking aid is triallyl isocyanurate.

[0037] The method for preparing the above-mentioned highly elastic three-dimensional mesh support structure comprises the following steps: S1. Evenly mix a POE elastomer having a melting point of ≤90° C., an elastomer containing an ethylenic polymerizable monomer, an antioxidant and a crosslinking aid, melt the mixture at 150° C., extrude and granulate the mixture, and obtain composite material particles; S2. After the composite particles are melted, they are extruded and cut into fibers. The fibers are curled and entangled with each other in a molten state and then put into cooling water at a temperature of 10°C. After cooling and solidification, they are formed and irradiated with a dose of 100 kGy to form a high-elastic three-dimensional mesh support structure. By controlling the pulling rate of the fibers, the density of the high-elastic three-dimensional mesh support structure is controlled to 200 kg / m 3 , the thickness after surface flattening is 1 cm.

[0038] Table 1 Amount of raw materials used in the high elastic three-dimensional mesh support structure in Examples 1-6 Example 2-5: A highly elastic three-dimensional mesh support structure, which is different from Example 1 in that the amounts of raw materials used are as shown in Table 1.

[0039] Example 6: A highly elastic three-dimensional mesh support structure, which is different from Example 3 in that it also includes a filler and a flame retardant. The amounts of the raw materials are shown in Table 1. The filler is talcum powder and the flame retardant is aluminum hydroxide. The preparation method of the highly elastic three-dimensional mesh support structure includes the following steps: S1, uniformly mixing a POE elastomer with a melting point of ≤90°C, an elastomer containing an ethylenic polymerizable monomer, a filler, a flame retardant, an antioxidant and a crosslinking aid, melting at 150°C, and extruding and granulating to obtain composite material particles; S2. After the composite particles are melted, they are extruded and cut into fibers. The fibers are curled and entangled with each other in a molten state and then put into cooling water at a temperature of 45°C. After cooling and solidification, they are formed and irradiated with a dose of 100 kGy to form a high-elastic three-dimensional mesh support structure. By controlling the pulling rate of the fibers, the density of the high-elastic three-dimensional mesh support structure is controlled to 200 kg / m 3 , the thickness after surface flattening is 1 cm.

[0040] Example 7: A highly elastic three-dimensional mesh support structure, which is different from Example 3 in that the elastomer containing olefinic polymerizable units is polyisoprene.

[0041] Example 8: A highly elastic three-dimensional mesh support structure. The difference from Example 3 is that POE is an ethylene-butene copolymer, model 7447, and density 0.865 g / cm 3 , the melt flow rate (190°C, 2.16kg) is 5g / 10min.

[0042] Example 9: A highly elastic three-dimensional mesh support structure. The difference from Example 3 is that POE is an ethylene-butene copolymer, model 7447, and density 0.865 g / cm 3 , the melt flow rate (190° C., 2.16 kg) is 5 g / 10 min, and the elastomer containing ethylenic polymerizable units is polyisoprene.

[0043] Embodiment 10: A highly elastic three-dimensional mesh support structure. The difference from Embodiment 3 is that the POE elastomer with a melting point of ≤90°C is a propylene-ethylene copolymer, model APP399.

[0044] Example 11: A highly elastic three-dimensional mesh support structure. The difference from Example 3 is that the POE elastomer with a melting point ≤ 90°C is a propylene-ethylene copolymer, and the elastomer containing olefinic polymerizable units is polyisoprene.

[0045] Comparative Example Comparative Example 1: A highly elastic three-dimensional mesh support structure, which is different from Example 1 in that an ethylene-octene copolymer with a melting point greater than 90°C is used, the model is 8450, and the density is 0.902 g / cm 3 , the melt index is 3g / 10min.

[0046] Comparative Example 2: A highly elastic three-dimensional mesh support structure, which differs from Example 10 in that isotactic polypropylene is used in equal amounts to replace propylene-ethylene copolymer.

[0047] Comparative Example 3: A highly elastic three-dimensional mesh support structure, which differs from Example 1 in that an equal amount of polyethylene is used to replace the ethylene-octene copolymer.

[0048] Comparative Example 4: A three-dimensional network structure with light weight and high elasticity, the raw materials are as follows: 60wt% dimethyl terephthalate / 1,4-butanediol, 40wt% polytetramethylene ether glycol with a molecular weight of 1000, and the preparation method is as follows: the raw materials are fed into an extruder, melted at 250°C, and transported to a spinning plate through a metering pump, infrared heat preservation is used between the spinning plate and the water tank to avoid premature solidification of thin solid special-shaped fibers before interlacing, and the woven fibers are compressed and molded by a mold in warm water at 15°C to obtain a three-dimensional network structure, and the density of the three-dimensional network structure is controlled at 48kg / m by controlling the traction rate.3 .

[0049] Performance testing The three-dimensional network structure prepared in the embodiment and the comparative example, and the three-dimensional network structure prepared in comparative example 4 were made into two samples with a thickness of 1 cm and a thickness of 5 cm by controlling the traction speed, namely sample A and sample B, and then the performance was tested according to the following method.

[0050] 1. Rebound rate: Test according to GB / T12622-2008 "Test method for compression rate and rebound rate of gaskets for pipe flanges". The higher the rebound rate, the greater the elasticity.

[0051] 2. 40% indentation hardness: at a constant temperature of 23°C, place the product between the upper and lower pressure plates, test at a speed of 100mm / min, compress to a strain of 40%, and press the product downward with the upper pressure plate. The load cell at the upper end will feel the pressure and convert it into a voltage signal to be analyzed by the display. The pressure value will be displayed on the screen in N. The test is repeated 3 times and the average value is taken.

[0052] 3. Compression permanent deformation rate: Under a constant temperature of 70℃, 50% compression deformation, after 22 hours, observe the change in thickness of the product after recovery. Compression permanent deformation = (difference in thickness before and after the product test) / thickness before the product test × 100%, test three times and take the average value.

[0053] 4. Fatigue resistance and repeated compression deformation rate: At a constant temperature of 23℃, place the product on the platform of the repeated compression tester, and repeatedly compress the product at a frequency of 70 times per minute, with a compression deformation of 50%. After 80,000 times, evaluate the performance of the product. Fatigue resistance and repeated compression deformation rate = (difference in thickness before and after the test) / thickness before the test × 100%, and take the average value of three tests.

[0054] Table 2 Performance test of high elastic three-dimensional mesh support structure In Examples 1-6, ethylene-octene copolymer and EPDM are used as cross-linking components, and raw materials such as cross-linking aids are used. After granulation, extrusion into fibers, cooling molding, and irradiation, a mesh three-dimensional support structure is made. The data in Table 2 show that the mesh three-dimensional support structure made in Examples 1-6 has a high rebound rate, a low 40% indentation hardness, is relatively soft, and has a small permanent compression deformation rate and fatigue resistance repeated compression deformation rate, and has a good deformation resistance effect.

[0055] In Examples 7-11, POE elastomer with a melting point of ≤90° C. and EPDM or polyisoprene are used as cross-linking components, and the three-dimensional network support structure has good resilience, softness, supporting force and deformation resistance.

[0056] In Comparative Example 1, a POE elastomer with a melting point higher than 90°C is used, in Comparative Example 2, isotactic polypropylene is used, and in Comparative Example 3, a polyolefin-based substance is used to replace the POE elastomer with a melting point less than or equal to 90°C. It can be seen from the data in Table 2 that the resilience, compression deformation resistance and other properties of the network three-dimensional support structure prepared in Comparative Examples 1-3 are reduced.

[0057] Comparative Example 4 is a mesh structure prepared by the prior art, and samples of different thicknesses are made respectively. It is found through testing that even if the thickness of the mesh structure made of thermoplastic polyester elastomer is controlled to 1 cm, the rebound effect of the present application cannot be achieved.

[0058] This specific embodiment is merely an explanation of the present application and is not a limitation of the present application. After reading this specification, those skilled in the art may make modifications to the present embodiment without any creative contribution as needed, but such modifications are protected by the patent law as long as they are within the scope of the claims of the present application.

Claims

1. A highly elastic three-dimensional mesh support structure, characterized in that: The invention is prepared by granulating, extruding, molding and irradiating the following raw materials in parts by weight: 10-90 parts of POE elastomer with a melting point of ≤90°C, 10-90 parts of elastomer containing olefinic polymerizable units, 0.1-5 parts of a crosslinking aid and 0.01-0.5 parts of an antioxidant.

2. The highly elastic three-dimensional mesh support structure according to claim 1, characterized in that: The POE elastomer with a melting point of ≤90° C. is selected from one or more of ethylene-butene copolymer and ethylene-octene copolymer.

3. The highly elastic three-dimensional mesh support structure according to claim 1, characterized in that: The elastomer containing ethylenic polymerizable units is selected from at least one of EPDM, polybutadiene, polyisoprene, styrene-butadiene copolymer, acrylonitrile-butadiene copolymer, methyl methacrylate-butadiene copolymer, acrylonitrile-isoprene copolymer, methyl methacrylate-isoprene copolymer, isoprene-styrene copolymer, chloroprene rubber, natural rubber, and butyl rubber.

4. The highly elastic three-dimensional mesh support structure according to claim 1, characterized in that: The highly elastic three-dimensional mesh support structure is made of the following raw materials in parts by weight through granulation, extrusion, molding and irradiation: 30-70 parts of ethylene-octene copolymer, 30-70 parts of EPDM, 0.1-5 parts of crosslinking aid, 0.01-0.5 parts of antioxidant, 1-50 parts of filler and 1-30 parts of flame retardant.

5. The highly elastic three-dimensional mesh support structure according to claim 4, characterized in that: The highly elastic three-dimensional mesh support structure is made of the following raw materials in parts by weight through granulation, extrusion, molding and irradiation: 30-70 parts of ethylene-butene copolymer, 30-70 parts of EPDM, 1.5-3.5 parts of crosslinking aid, 0.1-0.3 parts of antioxidant, 1-50 parts of filler and 1-30 parts of flame retardant.

6. The high elastic three-dimensional mesh support structure according to claim 1, characterized in that: The cross-linking aid is selected from at least one of triallyl isocyanurate, trimethylolpropane trimethacrylate and dicumyl peroxide.

7. The highly elastic three-dimensional mesh support structure according to claim 1, characterized in that: The antioxidant comprises a hindered phenol antioxidant and a phosphite antioxidant in a mass ratio of 2-5:

1.

8. The highly elastic three-dimensional mesh support structure according to claim 1, characterized in that: The density of the highly elastic three-dimensional mesh support structure is 20-200 kg / m 3 .

9. The highly elastic three-dimensional mesh support structure according to claim 1, characterized in that: The thickness of the highly elastic three-dimensional mesh support structure is ≤1 cm.

10. A high-elastic seat, characterized in that: It comprises an inner lining layer made by cutting and bonding the highly elastic three-dimensional mesh support structure according to any one of claims 1 to 9.

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