A composite structure of silicone leather and polyurethane sponge

Abstract

The present invention provides a composite structure for laminating silicone leather to polyurethane sponge, belonging to the technical field of sponge product processing. The structure comprises a sponge layer feed roller, a silicone layer feed roller, a gluing structure, a dipping structure, a rolling structure, and a rewinding structure. The gluing structure comprises a plurality of dipping units, each comprising an upwardly opening vibration trough, a plurality of steel balls positioned within the vibration trough, and a magnetic roller rotatably connected to the opening of the vibration trough. The magnetic roller has a plurality of magnetic elements uniformly arranged circumferentially around its circumference. The gluing structure applies glue to the composite surface of the silicone layer, which then passes through the magnetic roller of the first dipping unit. The rolling structure rolls the composite layer drawn from the last dipping unit. The rewinding structure rewinds the rolled composite layer. The rotation of the magnetic roller causes the steel balls within the vibration trough to be adsorbed onto the outer surface of the silicone layer at the magnetic roller. The steel balls, magnetically attracted by the magnetic roller, can break away from the magnetic roller's adsorption and fall into the vibration trough as the silicone layer and the magnetic roller gradually separate. The present invention has advantages such as high peel strength.

Description

Technical Field

[0001] The invention belongs to the technical field of sponge product processing and relates to a composite structure of silicone leather and polyurethane sponge. Background Art

[0002] With the increasing number of cars on the road and consumers' increasing demands for enhanced ride comfort, the automotive industry chain is placing increasingly stringent demands on automotive interior materials. Among these, issues such as odor / VOC, aging, yellowing / shedding, and cleaning and maintenance are becoming increasingly important concerns for automakers and the automotive industry chain. Mainstream PVC leather-laminated polyurethane sponge products and PU leather-laminated polyurethane sponge products for automotive interiors are increasingly criticized by consumers due to excessive odor / VOC levels, susceptibility to aging, yellowing, and shedding, and difficulty in cleaning and maintenance. The development of leather-laminated sponge products that are low in odor, low in VOC, less susceptible to aging, yellowing, and shedding, and easy to clean and maintain, while also being more affordable than genuine leather (cowhide, sheepskin, pigskin)-laminated polyurethane sponge products, has become a pressing need for consumers and industry players.

[0003] The applicant's prior application for a sponge product of silicone bonded to polyurethane sponge (application number: 202411339853.8) involves the compounding of silicone and sponge. In the prior art, the compounding of the two sheets is generally achieved by rolling the composite surface with glue. However, in the process of compounding the polyurethane sponge and silicone, due to the special pore structure of the sponge, its bonding surface is different from other flat bonding surfaces. It is difficult to achieve a uniform glue layer after one coating, and it is also impossible to fully utilize the pore structure to achieve strong bonding. Therefore, in the sponge product formed by bonding the sponge and silicone, it is difficult to achieve the ideal effect by using traditional methods to compound the two structures. Summary of the Invention

[0004] The purpose of the present invention is to provide a composite structure of silicone leather bonded with polyurethane sponge in order to solve the above-mentioned problems existing in the existing technology. The technical problem to be solved by the present invention is how to improve the peeling strength between the silicone layer and the sponge layer.

[0005] The objectives of the present invention can be achieved through the following technical solutions: a composite structure for laminating silicone leather to polyurethane sponge, characterized in that it includes a sponge layer feeding roller, a silicone layer feeding roller, a gluing structure, a dipping structure, a rolling structure and a winding structure, the dipping structure includes a plurality of dipping units, the dipping unit includes a vibration groove with an upward opening, a plurality of steel balls located in the vibration groove and a magnetic roller rotatably connected to the opening of the vibration groove, the circumferential surface of the magnetic roller is evenly arranged with a plurality of magnetic suction parts, the gluing structure applies glue to the composite surface of the silicone layer and then passes it through the magnetic roller of the first dipping unit, the rolling structure rolls the composite layer pulled out from the last dipping unit, and the winding structure winds up the rolled composite layer, the rotation of the magnetic roller can make the steel balls in the vibration groove adsorbed on the outer surface of the silicone layer at the magnetic roller, and the steel balls magnetically adsorbed by the magnetic roller can break away from the adsorption of the magnetic roller and fall into the vibration groove during the gradual separation of the silicone layer and the magnetic roller.

[0006] Furthermore, a sponge traction roller for traction of the sponge layer and a silicone traction roller for traction of the silicone layer are arranged between adjacent dipping units. The sponge traction roller is located above the silicone traction roller. The composite structure also includes a scraping roller that corresponds one-to-one to the silicone traction roller and cooperates with the silicone traction roller to clamp the silicone layer.

[0007] Furthermore, the magnetic attraction member is a permanent magnetic strip parallel to the axis of the magnetic roller.

[0008] As another option, the magnetic member is an electromagnetic strip in a strip shape parallel to the axis of the magnetic roller.

[0009] Furthermore, the outer wall of the magnetic roller is covered with a buffer layer.

[0010] Silicone sponge composite products are artificial leather formed by gluing the composite surface of the silicone layer and then compounding it with sponge. They have the characteristics of low VOC content, high peel strength, and good comfort. The sponge used is a sheet formed by cutting thick sponge blanks, which makes the foam distribution on the composite surface of the sponge irregular. The traditional gluing method is suitable for sheets with smooth composite surfaces. In this solution, in order to further highlight the greater peel strength after the sponge and silicone leather material are compounded, and to achieve a better transition between the two materials of sponge and silicone leather, multiple dipping methods are used for bonding. Specifically, liquid glue is applied to the silicone The composite surface of the layer, and then enters the position of the first magnetic roller with the sponge layer. The rotation of the magnetic roller drives the steel balls in the vibration groove to frequently adsorb and collide with the outer side of the silicone layer and break away from the adsorption of the magnetic roller. The steel balls frequently hit and squeeze the outer side of the silicone layer, so that the glue on the silicone layer can better penetrate into the broken wall pores of the sponge composite surface. Since the glue on the silicone layer is relatively uniform, the distribution of the broken wall pores on the sponge composite surface, the size of the pore rupture, and the pore distribution position are all random. Therefore, it is difficult to make the glue on the sponge composite surface by directly compounding the sponge and the silicone layer. Effective and uniform coating, in this scheme, Gujiao traction roller, sponge traction roller and scraping roller are set between adjacent dipping units to separate the sponge and silicone layer after the dipping unit, and the glue remaining on the composite surface of the silicone layer is rolled evenly for a second time by the scraping roller, and then the next dipping unit is used to perform sponge dipping again in the state of the two materials being bonded. This process is repeated to form a sponge dipping layer with uniform glue distribution and uniform filling of broken cell glue at the composite layer of the sponge. The sponge dipping layer is a transition layer combining the sponge material and the silicone cortical material. After the glue is cured, This transition layer can not only improve the peeling strength of the two materials separating from each other, but also form a transition between the two materials with different properties such as softness and elongation, so that the composite material can better rebound and retain its shape under external force interference such as rubbing, squeezing, and stretching, and the sponge layer is less likely to tear locally, and the overall mechanical strength of the composite material is higher; the silicone skin layer itself is formed by one-time curing of silicone, and the glue used in the composite process of the sponge and the silicone skin layer is also silicone glue. Therefore, the silicone glue penetrates outward to a certain thickness on the composite surface of the sponge, which can greatly improve the bonding strength between the two and the integrity after composite. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Figure 1 It is a structural diagram of this composite mechanism.

[0012] Figure 2 It is a cross-sectional view of the magnetic roller.

[0013] Figure 3 yes Figure 1 Enlarged view of part A in the middle.

[0014] In the figure, 1. Sponge layer feeding roller; 2. Silicone layer feeding roller; 3. Gluing structure; 4. Rolling structure; 5. Vibration groove; 6. Steel ball; 7. Magnetic roller; 8. Magnetic suction part; 9. Silicone traction roller; 10. Glue scraping roller; 11. Buffer layer; 12. Sponge traction roller. DETAILED DESCRIPTION

[0015] The following are specific embodiments of the present invention and the accompanying drawings to further describe the technical solutions of the present invention, but the present invention is not limited to these embodiments.

[0016] Silicone leather laminated polyurethane sponge products are composed of a release film layer, a hand-feel layer, a silicone skin layer, and a polyurethane sponge layer from top to bottom. The release film layer is a PET silicone release film with a thickness of 25 to 75 μm and a release force of 5 to 20 gf / inch. The hand-feel layer includes three components: a surface treatment agent, a catalyst, and a diluent. The silicone skin layer is 0.1 to 0.3 mm thick and includes components A and B. The polyurethane sponge is a polyester sponge or a polyether sponge with a thickness of 2 to 10 mm and an air permeability of 150 L / m2 / s to 1500 L / m2 / s. 2 Silicone leather-laminated polyurethane sponge products offer a comfortable and delicate touch, are scratch-resistant, low in odor and VOC, will not age, yellow, or fall off after long-term use, and are easy to maintain and clean. These products meet the performance demands of consumers for leather-laminated sponge products for automotive interiors.

[0017] The surface treatment agent, diluent, and catalyst were weighed in proportion and stirred and dispersed using a high-speed disperser at 1000 RPM for 1 minute to obtain a hand-feeling oil. Subsequently, the hand-feeling oil was coated onto the release film using an automatic coating machine or a manual coating machine according to the designed thickness. The film was then placed in a forced air drying oven at 130°C to 150°C for 3 minutes to obtain a hand-feeling layer with a release film.

[0018] Mix components A and B in proportion and stir and disperse them in a high-speed mixer at 1000 RPM for 3 minutes to obtain the silicone skin layer. Then weigh components A and B in a 1:1 ratio and stir and disperse them at 500 RPM for 2 minutes to obtain the liquid silicone for the silicone skin layer. Then, use an automatic or manual applicator to apply the liquid silicone to the designed thickness on the feel layer with the release film. Finally, heat and cure it in a forced air drying oven at 130°C to 150°C for 2 minutes to obtain the silicone skin layer with the release film and feel layer. From top to bottom, the following sequence is obtained: silicone skin layer, feel layer, release film.

[0019] like Figure 1 As shown, the prepared mixed silicone skin layer is coated on the silicone skin layer with liquid silicone using the coating structure 3 according to the designed thickness, so that the silicone skin layer and the sponge layer are Figure 1The composite structure shown in the figure undergoes processing through multiple dipping units, which not only achieves a more uniform distribution of adhesive liquid in the sponge pores, but also a secondary distribution and rolling of the adhesive liquid on the surface of the silicone skin layer by a scraping roller 10, ensuring uniform adhesive liquid distribution on the sponge composite surface, filling the pores, and achieving a uniform dipping thickness. After rolling, drying, and natural cooling, the composite product is composed of, from top to bottom, a sponge layer, a silicone skin layer, a hand-feel layer, and a release film (protective film). When in use, the release film can be removed.

[0020] The release film of the prepared silicone leather laminated polyurethane sponge product with a release film is peeled off, and then the silicone leather laminated polyurethane sponge product is pressed into the desired leather texture by an embossing machine to obtain the desired silicone leather laminated polyurethane sponge product.

[0021] For other parameters of the sponge product, reference may be made to the applicant's prior application with application number 202411339853.8.

[0022] like Figure 1 、 Figure 2 and Figure 3 The composite mechanism shown includes a sponge layer feeding roller 1, a silicone layer feeding roller 2, a gluing structure 3, a dipping structure, a rolling structure 4 and a winding structure. The dipping structure includes several dipping units, and the dipping unit includes a vibration groove 5 with an upward opening, several steel balls 6 located in the vibration groove 5 and a magnetic roller 7 rotatably connected to the opening of the vibration groove 5. Several magnetic suction parts 8 are evenly arranged on the circumferential surface of the magnetic roller 7. After the gluing structure 3 applies glue to the composite surface of the silicone layer, it passes through the magnetic roller 7 of the first dipping unit. The rolling structure 4 rolls the composite layer pulled out from the last dipping unit, and the winding structure winds up the rolled composite layer. The rotation of the magnetic roller 7 can make the steel balls 6 in the vibration groove 5 adsorbed on the outer surface of the silicone layer at the magnetic roller 7. The steel balls 6 magnetically adsorbed by the magnetic roller 7 can break away from the adsorption of the magnetic roller 7 and fall into the vibration groove 5 during the gradual separation of the silicone layer and the magnetic roller 7. A sponge traction roller 12 for traction of the sponge layer and a silicone traction roller 9 for traction of the silicone layer are arranged between adjacent dipping units. The sponge traction roller 12 is located above the silicone traction roller 9. The composite structure also includes a scraping roller 10 which corresponds one-to-one to the silicone traction roller 9 and cooperates with the silicone traction roller 9 to clamp the silicone layer.

[0023] The magnetic element 8 is a permanent magnet parallel to the axis of the magnetic roller 7, or it can be an electromagnetic strip. The magnetic force can be controlled to adjust the impact intensity. The outer wall of the magnetic roller 7 is covered with a buffer layer 11 to protect the sponge layer and improve the synchronization between the magnetic roller 7 and the sponge.

[0024] It should be noted here that: in the prior art, roller pressing is generally used to bond composite materials. However, sponge materials have their own particularities. The sponge involved in this solution is a sponge with a certain air permeability. The air permeability of the sponge is inconsistent in different parts of the sponge. This is because the pore distribution of the sponge after foaming is regular, and the bubble breaking diameter and bubble breaking position at different positions after slicing are not uniform. Therefore, if roller pressing is performed directly after gluing, the glue will have a greater penetration thickness on the sponge at some positions, while some positions will have less glue penetration. In this solution, after the glue is applied once, it is dipped in glue for multiple times. The point-like hitting method is different from the roller pressing method. The point-like hitting method is different from the roller pressing method. The beating method and the multi-point extrusion method can prevent the glue in the position with strong permeability from penetrating the outside of the sponge to a large extent. The extrusion posture is scattered, which is conducive to the diffusion and penetration of the glue in the surface area of ​​the sponge composite surface. The roller pressing method is actually a plane compression sponge due to the compressibility of the sponge, not a linear compression sponge. The penetration direction of the glue tends to the outer side of the sponge. Therefore, the point pressure method used in this scheme is conducive to the uniform distribution of glue on the irregular sponge composite surface, forming a transition layer with relatively uniform thickness on one side of the sponge composite surface. If this transition layer is uneven, it will not only affect the overall feel of the composite material, but also cause unevenness on one side of the sponge.

[0025] The scraping roller 10 is used to drive the secondary distribution of glue on the glue-coated surface of the silicone skin layer. Due to the irregularity of the sponge composite surface, the glue distribution on the silicone skin layer composite surface, which was originally evenly coated, is not uniform after the two materials are separated again. After the scraping roller 10 rolls it, the glue on its surface can be evened out again.

[0026] The sponge composite sheet prepared by this solution has stable hand feel, high strength, uniform material thickness and good integrity.

[0027] The specific embodiments described herein are merely illustrative of the spirit of the present invention. Persons skilled in the art may make various modifications, additions, or substitutions to the described specific embodiments without departing from the spirit of the present invention or exceeding the scope of the appended claims.

Claims

1. A composite structure of silicone leather and polyurethane sponge, characterized in that: The present invention comprises a sponge layer feeding roller (1), a silicone layer feeding roller (2), a glue coating structure (3), a glue dipping structure, a rolling structure (4) and a winding structure, wherein the glue dipping structure comprises a plurality of glue dipping units, the glue dipping units comprising a vibration groove (5) with an opening facing upward, a plurality of steel balls (6) located in the vibration groove (5) and a magnetic roller (7) rotatably connected to the opening of the vibration groove (5), a plurality of magnetic suction parts (8) are uniformly arranged on the circumference of the magnetic roller (7), and the glue coating structure (3) is provided on the composite of the silicone layer. After the surface is coated with glue, it passes through the magnetic roller (7) of the first dipping unit, the rolling structure (4) rolls the composite layer pulled out from the last dipping unit, and the winding structure winds up the rolled composite layer. The rotation of the magnetic roller (7) can make the steel balls (6) in the vibration groove (5) adsorbed on the outer surface of the silicone layer at the magnetic roller (7). The steel balls (6) magnetically adsorbed by the magnetic roller (7) can break away from the adsorption of the magnetic roller (7) and fall into the vibration groove (5) during the gradual separation of the silicone layer and the magnetic roller (7).

2. A composite structure of silicone leather and polyurethane sponge according to claim 1, characterized in that: A sponge traction roller (12) for traction of the sponge layer and a silicone traction roller (9) for traction of the silicone layer are provided between adjacent dipping units. The sponge traction roller (12) is located above the silicone traction roller (9). The composite structure further comprises a scraping roller (10) corresponding to the silicone traction roller (9) and cooperating with the silicone traction roller (9) to clamp the silicone layer.

3. A composite structure of silicone leather and polyurethane sponge according to claim 1 or 2, characterized in that: The magnetic attraction member (8) is a permanent magnetic strip parallel to the axis of the magnetic roller (7).

4. A composite structure of silicone leather and polyurethane sponge according to claim 1 or 2, characterized in that: The magnetic attraction member (8) is a strip-shaped electromagnetic strip parallel to the axis of the magnetic roller (7).

5. A composite structure of silicone leather and polyurethane sponge according to claim 1 or 2, characterized in that: The outer wall of the magnetic roller (7) is covered with a buffer layer (11).

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