Adhesive-free laminating preparation method and forming method of elastic cushion

Abstract

The invention discloses a glue-free bonding preparation method of an elastic cushion, which comprises the following steps: providing a base material which comprises a sheet body formed by mixing natural rubber added with a foaming agent and a related additive and then pressing, arranging a destroying material which comprises the foaming agent and a foaming promoter on the surface of the base material, and instantly heating the destroying material to form the elastic cushion. The method comprises the following steps: placing a destroying material on a substrate, enabling the destroying material to generate a chemical reaction to destroy the surface of the substrate, attaching a surface material to the surface of the substrate, heating the attached substrate and surface material to enable the substrate to be partially ripened, and simultaneously applying a strengthening means and applying an external force to the surface material, so that the destroying material on the contact surface of the surface material and the substrate is strengthened by the external force. Therefore, the plane material and the base material can be connected more easily. Applying pressure to the outer sides of the surface material and the base material so as to promote the surface material to be attached to the base material, and finally heating the surface material and the base material so that the base material is completely ripened to obtain the elastic cushion.

Description

Technical Field

[0001] The present application relates to the field of material technology, and in particular to a method for preparing an elastic pad by glue-free bonding. Background Art

[0002] Generally, elastic pads are formed by laminating a rubber sheet with a surface material of different physical properties (such as fiber cloth, etc.). The technology for laminating the rubber sheet and the surface material is to apply a glue or adhesive on the surface of the rubber sheet before it is matured and fixed, and then the surface material is placed on the rubber sheet and sent to a vulcanization foaming box for ripening, so that the elastic pad can be foamed. However, this method of laminating the surface material and the rubber sheet with a glue or adhesive will cause environmental problems such as air and water pollution during the production process.

[0003] To this end, the inventor developed the "Method for Preparing Continuous Rubber Embossed Foam" in Taiwan Publication No. 200607634 many years ago. It mainly uses the gas pressure generated by the chemical change of the foaming agent added to the rubber sheet material to bond the surface material without using adhesives or adhesives. The inventor calls it glue-free bonding technology. This process is more environmentally friendly and is currently widely used in the industry.

[0004] Secondly, in order to solve the problems in the prior art, such as the slow water absorption speed of the woven cloth absorbent mat, and the poor feeling of stepping on the hard diatomaceous earth (diatomaceous earth) absorbent mat, easy to break and easy to slip (need to be used with an anti-slip mat), the inventor has successively developed the elastic absorbent mats of Taiwan Invention No. I693909, No. I 729845 and the new patent No. M582806, No. M601062 in recent years. It not only absorbs water faster, but also feels soft when stepped on and will not slip on the ground. Therefore, it can indeed solve the shortcomings of the use of different types of absorbent mats in the prior art, and these elastic absorbent mats have been sold in most merchants and mass merchandising channels, and consumers have reported very good experience in use. These elastic absorbent mats are also elastic mats, and the bonding method of the surface material and the rubber sheet body also uses the glue-free bonding technology of the elastic mat. However, it is still necessary to further improve the bonding degree between the surface material and the rubber sheet body. Summary of the invention

[0005] In order to solve the above technical problems, the present application discloses a glue-free lamination preparation method for an elastic pad.

[0006] To achieve the above-mentioned purpose of the invention, the glue-free lamination preparation method of the elastic pad of the present application at least includes:

[0007] Providing a substrate: providing a substrate, the substrate comprising a sheet formed by kneading and pressing natural rubber and related additives; setting a destructive material: setting a destructive material on the surface of the substrate, the destructive material comprising a mixed foaming agent and a foaming aid; instant heating: instant heating the destructive material so that the destructive material produces a chemical reaction and destroys the surface of the substrate; attaching a surface material: attaching a surface material to the surface of the substrate where the destructive material is provided; heating and strengthening: heating and bonding the substrate and the surface material to partially mature the substrate, and simultaneously applying a strengthening means, the strengthening means comprising applying an external force to the surface material so that the destructive material on the contact surface of the surface material and the substrate is strengthened by the external force, so that the surface material and the substrate are easier to connect; applying pressure: applying pressure to the outer sides of the surface material and the substrate to promote the bonding of the surface material and the substrate; maturation: heating the surface material and the substrate so that the substrate is fully matured, thereby obtaining an elastic pad.

[0008] Preferably, in the step of providing the substrate, the substrate is placed on a continuously moving support, and after the aging step, the elastic pad is separated from the support, and the support includes an embossing mold that can produce texture on one side of the substrate.

[0009] Preferably, the destroying material further comprises a defoaming agent, a defoaming agent and / or an elastic material.

[0010] Preferably, the substrate and the destructive material further include water-absorbing material powder.

[0011] Preferably, in the instantaneous heating step, the instantaneous heating temperature is at least a temperature at which the foaming agent can produce a chemical reaction and generate gas.

[0012] Preferably, in the step of attaching the surface material, the surface material is a fiber sheet.

[0013] Preferably, in the heating and strengthening step, the strengthening means may be any one of physical means such as wind, radio waves, laser or magnetic waves, or a combination of at least two of them.

[0014] Preferably, the strengthening means is wind force, so that part of the surface of the substrate and part of the damaged material can extend into the surface material.

[0015] Preferably, the strengthening means is negative pressure wind force.

[0016] Preferably, in the heating and strengthening step, the substrate is partially ripened, and in the fully ripening step, heating is performed at least once until the substrate is completely ripened.

[0017] Compared with the prior art, the present invention has the following beneficial effects:

[0018] The adhesive-free bonding method of the elastic pad provided in the present application only utilizes the destructive effect of the destructive material on the surface of the substrate when it is instantly heated and undergoes chemical changes, and cooperates with the strengthening means applied to the surface material to bond the substrate and the surface material with different physical properties, without the need for adhesives, and is more environmentally friendly.

[0019] A support member separated from the substrate can also be used to form a predetermined texture on one side of the substrate.

[0020] Compared with the glue-free bonding production method of elastic pads in the prior art, the present application only utilizes the gas pressure generated by the foaming agent in the substrate to make the substrate bond to the surface material, which can improve the adhesion between the substrate and the surface material, and improve the adhesion between the surface material and the rubber sheet, making the surface material more difficult to separate from the substrate and more practical. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] In order to more clearly illustrate the glue-free bonding preparation method of an elastic pad described in the present application, the drawings required for the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative labor.

[0022] Figure 1 It is a flow chart of the glue-free lamination preparation of the elastic pad of the present application.

[0023] Figure 2 It is a structural schematic diagram of the first embodiment of the elastic pad of the present application.

[0024] Figure 3 It is a schematic diagram of the process of the glue-free bonding equipment of the elastic pad of the present application.

[0025] Figure 4 This is a schematic structural diagram of the second embodiment of the elastic pad of the present application.

[0026] Among them: 1-base material, 2-destructive material, 3-surface material, 4-supporting member, 10-elastic water-absorbent mat. DETAILED DESCRIPTION

[0027] The technical solutions in the embodiments of the present application will be described clearly and completely below in conjunction with the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, not all of the embodiments. Based on the embodiments in the present application, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of this application.

[0028] As used herein, "one embodiment" or "embodiment" refers to a specific feature, structure or characteristic that may be included in at least one implementation of the present application. The content of the present invention may be more easily understood by referring to the following detailed description of the preferred implementation method of the present invention and the included embodiments. Unless otherwise specified, all technical and scientific terms used herein have the same meaning as commonly understood by a person of ordinary skill in the art to which the present invention belongs. In the event of a conflict, the definitions in this specification shall prevail.

[0029] For the following defined terms, these definitions shall apply unless a different definition is given in the claims or elsewhere in this specification. All numerical values, whether or not explicitly indicated, are defined herein as modified by the term "about". The term "about" generally refers to a numerical range that a person of ordinary skill in the art considers to be equivalent to the stated values ​​to produce substantially the same properties, functions, results, etc. A numerical range indicated by a lower value and a higher value is defined to include all numerical values ​​included in the numerical range and all subranges included in the numerical range.

[0030] Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the invention are approximations, the numerical values ​​set forth in the specific examples are reported as precisely as possible. Any numerical value, however, inherently contains certain errors necessarily resulting from the standard deviation found in their respective testing measurements.

[0031] When a numerical range is disclosed herein, the above range is considered to be continuous and includes the minimum and maximum values ​​of the range, as well as each value between such minimum and maximum values. Further, when a range refers to an integer, each integer between the minimum and maximum values ​​of the range is included. In addition, when multiple ranges are provided to describe features or characteristics, the ranges can be merged. In other words, unless otherwise indicated, all ranges disclosed herein should be understood to include any and all sub-ranges included therein. For example, a specified range from "1 to 10" should be considered to include any and all sub-ranges between a minimum of 1 and a maximum of 10. Exemplary sub-ranges of ranges 1 to 10 include, but are not limited to, 1 to 6.1, 3.5 to 7.8, 5.5 to 10, etc.

[0032] It should be noted that the terms "first", "second", etc. in the specification and claims of the present application and the above-mentioned drawings are used to distinguish similar objects, and are not necessarily used to describe a specific order or sequence. It should be understood that the data used in this way can be interchanged where appropriate, so that the embodiments of the present application described herein can be implemented in an order other than those illustrated or described herein. In addition, the terms "including" and "having" and any variations thereof are intended to cover non-exclusive inclusions.

[0033] The following describes an embodiment to illustrate a method for preparing an elastic pad without adhesive bonding provided by the present application.

[0034] Embodiment 1

[0035] See also Figure 1-2 The first step is to provide a substrate 110: provide a substrate 1, which is a natural rubber extracted from rubber tree latex, and is added with a foaming agent (such as azodicarbonamide ADC / AC, a nitroso foaming agent, oxybisbenzenesulfonyl hydrazide, benzenesulfonyl hydrazide, etc., azodicarbonamide in this embodiment, but the use of other foaming agents is not limited) and a foaming aid (such as a promoter, an inhibitor, a stabilizer and a catalyst, etc.) and other additives, mixed with water-absorbing material powder (only when the elastic pad prepared by the present invention is used as a water-absorbing mat) and kneaded to form a sheet. The foaming agent, foaming aid and other additives are related additives in the prior art to control the foaming and vulcanization molding of natural rubber, which are prior art, and their detailed composition and foaming principle will not be repeated here.

[0036] The second step is to set the destructive material 120: a destructive material 2 is set on the surface of the substrate 1. The destructive material can be set on the surface of the substrate by coating or spraying, but other methods are not limited. The destructive material includes a foaming agent, a foaming aid, a defoaming agent / defoaming agent or / and a water-absorbing material powder (only when the elastic pad prepared by the present invention is used as a water-absorbing floor mat), an elastic material (liquid or solid), the foaming agent, the foaming aid and the additive of the substrate 1 are the same, but not limited, the defoaming agent / defoaming agent is a rubber product defoaming agent in the prior art, which is used to break the bubbles generated by the foaming agent on the surface of the substrate 1, and to adjust the foaming effect of the foaming agent. The water-absorbing material powder includes mineral powders such as diatomaceous earth, clay, sand, etc. or / and plant powders such as cotton and agar or / and chemical powders such as sludge, slag, super absorbent resin, nylon, polyacrylate, etc., but is not limited to the diatomaceous earth in this embodiment. The elastic material can be a thermoplastic elastic material in the prior art, such as PU (TPU), TPR and natural rubber, etc., but is not limited. The addition ratio of each foaming agent, foaming aid, defoaming agent, water-absorbing material powder and elastic material is not limited, and it only needs to be used to destroy the surface of the substrate 1. In addition, the water-absorbing material powder can be used to absorb moisture, and the elastic material is used for connection.

[0037] The third step is instant heating 130: instant heating the above-mentioned destructive material 2, so that the destructive material 2 produces a chemical reaction and then destroys the surface of the substrate 1. The instant heating temperature is at least the temperature at which the foaming agent and the defoaming agent can produce a chemical reaction. For example, the decomposition temperature of the azodicarbonamide foaming agent is about 195°C to 120°C, and the instant heating temperature is above 195°C. During instant heating, the surface of the substrate 1 will also be softened by heat, and it is easy to be damaged by the foaming gas pressure and the bubble breaking interaction of the foaming agent and the defoaming agent in the destructive material 2. In addition, when the elastic material added to the destructive material 2 is solid, the instant heating temperature can also soften the elastic material, and the softened elastic material can be destroyed and separated by the interaction of the foaming agent and the defoaming agent.

[0038] The fourth step is to attach the surface material 140: when the destructive material 2 produces a chemical reaction and destroys the surface of the substrate 1, the surface material 3 is laid on the surface of the substrate 1, and the substrate 1 and the surface material 3 can be gradually attached to each other due to the chemical reaction of the destructive material 2. The surface material 3 is a fiber sheet, such as cloth.

[0039] The fifth step is heating and strengthening 150: heating and bonding the substrate 1 and the surface material 3 and applying strengthening means at the same time. The strengthening means is to apply external force to the surface material 3 so that the surface material 3 and the substrate 1 are easier to connect. The aforementioned heating method is to input the substrate 1 and the surface material 3 into an oven. The surface material 3 and the substrate 1 can be naturally connected by the foaming gas pressure of the foaming agent in the destructive material 2 and the defoaming interaction of the defoaming agent. The heating temperature is such that the substrate 1 can be matured to about half-mature. The strengthening means is carried out in the oven, but other heating facilities outside the oven are not limited. The strengthening means can be any one or a combination of at least two physical means such as wind, radio waves, lasers or magnetic waves. The strengthening means can directly reach the destructive material 2 through the material gap of the surface material 3 and improve the connection between the destructive material 2 and the surface material 3. Moreover, the softened and separated elastic material in the destructive material 2 can further assist in connecting the surface material 3 and the substrate 1.

[0040] The sixth step is to apply pressure 160: after the surface material 3 and the substrate 1 are strengthened, pressure is applied to the outer sides of the surface material 3 and the substrate 1 to promote the adhesion between the surface material 3 and the substrate 1. The pressure can be applied by inputting the surface material 3 and the substrate 1 into a pressing machine, but is not limited to using a pressing machine.

[0041] The last step of the present invention is curing 170, which includes heating the surface material 3 and the substrate 1 in an oven until the substrate 1 is completely cured, thereby obtaining a resilient water-absorbent floor mat 10. The surface material 3 and the substrate 1 can be cured by heating in one oven or by heating in multiple ovens.

[0042] Therefore, the adhesive-free bonding method 100 of the elastic pad of the present application utilizes the method of placing the destructible material 2 on the surface of the substrate 1 and then heating it instantly to cause the destructible material 2 to produce a chemical reaction and destroy the surface of the substrate 1, and then attaching the surface material 3 on the substrate 1, so that the substrate 1 and the surface material 3 can be naturally bonded due to the gas pressure generated by the foaming agent in the destructible material 2 and the interaction of the defoaming agent; then the substrate 1 and the surface material 3 are heated and a strengthening method is applied at the same time to improve the connection between the substrate 1 and the surface material 3, and finally, the substrate 1 and the surface material 3 can be bonded without an adhesive to form the elastic pad 10. Moreover, when water-absorbing material powder is added to the materials of the substrate 1 and the destructible material 2, the elastic pad 10 can be used as a water-absorbing floor mat.

[0043] Embodiment 2

[0044] See also Figure 3 The steps of the adhesive-free laminating method 200 of the elastic pad of the present application are generally the same as those of the adhesive-free laminating method 100, except that the substrate 1 is attached to a continuously moving support member 4 (for example, placed on a conveyor belt, not shown in the figure), and the support member 4 is a release cloth that can produce texture on one side of the substrate 1, but other materials are not limited. The support member 4 is separated from the elastic pad 10 after the aging step 170. Secondly, in the step of heating and strengthening 150, the strengthening means can be negative pressure wind force, so that part of the surface of the substrate 1 and part of the damage material 2 can be attracted by the negative pressure and extend into the surface material 3, such as Figure 4 In addition, the curing step 170 can be heated twice, and then the curing can be performed at 70%, 85% and finally completed. Thus, after the support member 4 is separated from the elastic pad 10, the surface of the substrate 1 can be affected by the support member 4 to form a predetermined pattern.

[0045] In addition, the present application can also prepare an elastic pad with multiple layers of fiber cloth (i.e., the surface material 3), and only needs to set a destructible material 2 containing elastic material between each layer of fiber cloth, and the destructible material 2 can be used to connect each layer of fiber cloth. Specifically, after repeating the steps of setting the destructible material 120, instant heating 130, attaching the surface material 140, and heating and strengthening 150 for several times, the steps of applying pressure 160 and aging 170 are performed. In addition, various types of recycled materials can also be added to the substrate 1 of the present invention, so that the present invention also has the effect of using recycled waste as materials.

[0046] As can be seen from the above, the glue-free bonding method of the elastic pad provided by the present application only utilizes the destructive effect of the destructive material on the surface of the substrate when it is heated and undergoes chemical changes instantly, and with the strengthening means applied to the surface material, the substrate with different physical properties can be bonded to the surface material without adhesive, which is more environmentally friendly. It is also possible to form a predetermined pattern on one side of the substrate by means of a support member that can be separated from the substrate. Compared with the glue-free bonding method of the elastic pad in the prior art, the present application only utilizes the gas pressure generated by the foaming agent in the substrate to bond the substrate to the surface material, which can make the adhesion between the substrate and the surface material better, and the surface material is less likely to be separated from the substrate, which is more practical.

[0047] Of course, the surface material in the manufacturing method of the present invention is not limited to cloth, and can also be made of materials such as plastic film, so as to enhance the diversity of elastic pad products and increase the use of the products.

[0048] The above disclosure is only the preferred embodiment of the present application. It should be pointed out that any changes made by technicians familiar with the field to the specific implementation of the present application do not deviate from the scope of the claims of the present application. Accordingly, the scope of the claims of the present application is not limited to the aforementioned specific implementation.

Claims

1. A method for preparing an elastic pad without adhesive bonding, characterized in that: The preparation method at least comprises the following steps: Providing a substrate: providing a substrate, the substrate comprising a sheet formed by kneading and pressing natural rubber and related additives; Setting a destructive material: Setting a destructive material on the surface of the substrate, wherein the destructive material comprises a mixed foaming agent and a foaming aid; Instant heating: instant heating of the destructive material to cause the destructive material to produce a chemical reaction and destroy the surface of the substrate; Laying a surface material: Laying a surface material on the surface of the substrate provided with the destructive material; Heating and strengthening: heating and bonding the substrate and the surface material to partially mature the substrate, and applying a strengthening means at the same time, the strengthening means includes applying an external force to the surface material so that the damaged material at the contact surface between the surface material and the substrate is strengthened by the external force, so that the surface material and the substrate are easier to connect; Applying pressure: applying pressure to the outer sides of the surface material and the substrate to promote the bonding between the surface material and the substrate; Curing: The surface material and the substrate are heated to fully cure the substrate, thereby obtaining an elastic pad.

2. The method for preparing an elastic pad without adhesive bonding according to claim 1, characterized in that: In the step of providing the substrate, the substrate is placed on a continuously moving support. After the curing step, the elastic pad is separated from the support, and the support includes an embossing mold that can produce textures on one side of the substrate.

3. The adhesive-free lamination preparation method according to claim 1 or 2, characterized in that: The destructive material also includes a defoaming agent, a defoaming agent and / or an elastic material.

4. A method for preparing adhesive-free bonding as claimed in claim 3, characterized in that: The substrate and the destructive material also include water-absorbing material powder.

5. The adhesive-free lamination preparation method according to claim 1 or 2, characterized in that: In the instant heating step, the instant heating temperature is at least a temperature at which the foaming agent can produce a chemical reaction and generate gas.

6. The adhesive-free bonding preparation method according to claim 1 or 2, characterized in that: In the step of attaching the surface material, the surface material is a fiber sheet.

7. The adhesive-free bonding preparation method according to claim 6, characterized in that: In the heating and strengthening step, the strengthening means may be any one of physical means such as wind, radio waves, laser or magnetic waves, or a combination of at least two of them.

8. The adhesive-free lamination preparation method according to claim 7, characterized in that: The strengthening means is wind force, so that part of the surface of the substrate and part of the damaged material can extend into the surface material.

9. The adhesive-free lamination preparation method according to claim 8, characterized in that: The strengthening means is negative pressure wind force.

10. The adhesive-free lamination preparation method according to claim 1 or 2, characterized in that: In the heating and strengthening step, the base material is partially ripened, and in the fully ripening step, heating is performed at least once until the base material is completely ripened.

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