Processing technology of double-sided rubber yoga mat

Abstract

The invention provides a double-sided rubber yoga mat processing technology which comprises the following steps: S1, respectively preparing an A-side natural rubber coiled material and a B-side natural rubber coiled material: carrying out plasticizing treatment on a natural rubber raw material at the plasticizing temperature of 60-90 DEG C for 10-30 minutes; s2, color master batches are added into the plasticized natural rubber for mixing, color master batches of different colors are adopted for the A face and the B face respectively, and the adding amount of the color master batches accounts for 1-5% of the total weight of the rubber; s3, the mixed rubber sizing material and fine cloth are synchronously fed into a foaming furnace through continuous compounding equipment, foaming forming is conducted at the temperature of 160-200 DEG C, and a coiled material formed by compounding a rubber layer with a porous structure on the surface and the fine cloth is formed; s4, the A-face coiled material and the B-face coiled material are continuously compounded through a hot pressing roller, and the hot pressing temperature is 120-150 DEG C; the problems that a traditional yoga mat is single in double-sided function, low in compounding process efficiency and high in interlayer stripping risk are solved.

Description

Technical Field

[0001] The present invention relates to the technical field of fitness equipment production, in particular to a processing technology for a double-sided rubber yoga mat. Background Art

[0002] At present, the natural rubber yoga mats sold on the market have the advantages of good anti-slip performance, good elasticity, wear resistance, etc., and have a certain market, but: the price is relatively high; the color is relatively single.

[0003] Traditional yoga mats mostly use single-layer foaming materials (such as PVC, TPE, etc.), and there are problems such as easy deformation, insufficient anti-slip performance, and poor environmental protection. Although the existing natural rubber yoga mats are environmentally friendly, the single-layer structure is difficult to meet the dual-sided differential performance requirements. In addition, the conventional composite process requires multiple laminations, resulting in low efficiency and weak interfacial bonding strength. Summary of the Invention

[0004] To overcome the above problems, the purpose of the present invention is to provide a processing technology for a double-sided rubber yoga mat that can achieve dual-sided differential performance and structural stability through dual-sided independent formula design, integral foaming molding, and continuous composite process.

[0005] The present invention is realized by the following scheme: A processing technology for a double-sided rubber yoga mat, the processing technology includes the following steps:

[0006] Step S1, respectively prepare the A-side natural rubber coil and the B-side natural rubber coil: plasticize the natural rubber raw material, the plasticizing temperature is 60-90 °C, and the plasticizing time is 10-30 minutes;

[0007] Step S2, add color masterbatch to the plasticized natural rubber for mixing, and different colors of color masterbatch are used for the A side and the B side respectively, and the addition amount of the color masterbatch is 1-5% of the total weight of the rubber;

[0008] Step S3, feed the mixed rubber compound and the fine cloth into the foaming furnace synchronously through a continuous composite device, and foam and form at 160-200

[0009] °C to form a coil in which a rubber layer with a porous structure on the surface is compounded with the fine cloth;

[0010] Step S4, continuously compound the A-side coil and the B-side coil through a hot pressing roller, the hot pressing temperature is 120-150 °C,

[0011] the pressure is 5-10 MPa, so that the A-side rubber layer and the B-side rubber layer are bonded through the intermediate fine cloth layer;

[0012] Step S5, cut the compounded coil according to a preset length, and cut it into the contour of the yoga mat by laser or die cutting, and polish the edge of the cut yoga mat.

[0013] Furthermore, the fine cloth in step S3 is a polyester fiber woven fabric with a gram weight of 50 - 120 g / ㎡. The fine cloth is pre-treated with plasma, and the surface roughness Ra is 1.2 - 2.5 μm.

[0014] Furthermore, the foaming furnace in step S3 has segmented temperature control. The foaming furnace is divided into a preheating section (160 - 170 °C), a foaming section (180 - 190 °C), and a shaping section (150 - 160 °C). The total foaming time is 5 - 8 minutes.

[0015] Furthermore, the masterbatch rubber is an environment-friendly water-based color paste, which contains the following components in parts by weight: natural rubber matrix: 100 parts; pigment particles: 5 - 15 parts; dispersant (fatty acid salt): 1 - 3 parts; antioxidant (type 1010): 0.5 - 1 part.

[0016] Furthermore, the surface of the hot press roller in step S4 is provided with micro-convex patterns with a pattern depth of 0.1 - 0.3 mm, which are used to form anti-slip textures on the surface of the rubber layer during the composite process.

[0017] Furthermore, the laser blanking in step S5 uses a CO2 laser with a power of 200 - 500 W, a cutting speed of 10 - 20 mm / s, and a cutting seam width ≤ 0.1 mm.

[0018] The beneficial effects of the present invention are as follows: The present invention has double-sided differential performance, meeting diverse usage requirements. Through double-sided independent formulation design, integral foaming molding, and continuous compounding process, double-sided differential performance and structural stability are achieved, while production efficiency is improved, solving the problems of single double-sided functions of traditional yoga mats, low efficiency of compounding process, and risk of interlayer peeling; customers can specify the color of natural rubber during the design of natural rubber products; two natural rubber coils with different colors, the same or different physical properties can be combined to realize the double-sided rubber production process; hardness difference: Through the independent formulation design of A / B sides, the double-sided touch feeling is differentiated, and users can choose the contact surface according to the type of exercise (for example, the A side is soft and suitable for meditation, and the B side has high hardness to provide exercise support); anti-slip texture controllable: The micro-convex texture on the surface of the hot pressing roller makes different anti-slip structures on both sides, and the friction coefficient difference can reach 0.2 - 0.4 (A side 0.8, B side 1.2, ASTM D1894 test), adapting to various scenarios such as wooden floors and lawns; the structural stability is significantly improved, and the service life is extended; interlayer bonding force: The integral foaming process enables the rubber and the fine cloth to form a physical interlock (non-glued), and the peel strength reaches 18.2 N / cm, with no risk of delamination during long-term use; tear resistance performance: The fine cloth reinforcement layer (polyester fiber or aramid) improves the tear strength of the finished product to 22.5 kN / m, and can withstand high-intensity stretching (such as frequent folding in hot yoga); wear resistance optimization: The fine cloth layer disperses stress, and the mass loss is only 0.9% after 10,000 Martindale tests, and the service life is extended by more than 3 times; zero solvent emission: The whole process uses water-based color masterbatch glue and natural rubber raw materials, and no benzene substances are detected in the VOC test (<0.01 ppm), meeting the EU REACH regulations and the US CARB standards; biodegradability: The main natural rubber material (accounting for ≥90%) has a degradation rate of >60% in 180 days under composting conditions (ISO 14855 test), far superior to PVC / TPE mats (degradation rate <5%); continuous production: The A / B sides are foamed and compounded synchronously, reducing the glue coating and curing links in the traditional process, with a production efficiency of 120 pieces per hour and an energy consumption reduction of 35%; low scrap rate: The laser cutting accuracy is ±0.1 mm, and the material utilization rate is increased to 95% (85% for traditional die cutting), and when the annual production capacity is 100,000 pieces, the raw material cost can be saved by 120,000 yuan; the resilience is optimized, and the buffering performance is more suitable for joint protection; lightweight design: The composite structure density ≤0.6 g / cm 3 (traditional PVC mat ≥0.8 g / cm 3 ), and the weight of the standard-size yoga mat is <1.2 kg, with a 20% improvement in portability. Description of the Drawings

[0019] Figure 1 is the schematic flow chart of the method of the present invention.

[0020] Figure 2 is the schematic structural diagram of the product of the present invention.

[0021] Figure 3 It is a cross-sectional view of a finished yoga mat.

[0022] In the figure: rubber layer - A, fine cloth layer - B. Specific implementation mode

[0023] The present invention will be further described below with reference to the accompanying drawings.

[0024] Please refer to Figure 1 As shown, a processing technology for a double-sided rubber yoga mat of the present invention includes the following steps:

[0025] Step S1, respectively prepare the A-side natural rubber coil and the B-side natural rubber coil: plasticize the natural rubber raw material, the plasticizing temperature is 60 - 90 °C, and the plasticizing time is 10 - 30 minutes;

[0026] Step S2, add color masterbatch to the plasticized natural rubber for mixing. Different color masterbatches are used for the A side and the B side respectively, and the addition amount of the color masterbatch is 1 - 5% of the total weight of the rubber;

[0027] Step S3, feed the mixed rubber compound and the fine cloth into the foaming furnace synchronously through a continuous compounding device, and foam and form at 160 - 200

[0028] °C to form a coil in which a rubber layer with a porous structure on the surface is compounded with the fine cloth;

[0029] Step S4, continuously compound the A-side coil and the B-side coil through a hot pressing roller, the hot pressing temperature is 120 - 150 °C,

[0030] The pressure is 5 - 10 MPa, so that the A-side rubber layer and the B-side rubber layer are bonded through the intermediate fine cloth layer;

[0031] Step S5, cut the compounded coil according to a preset length, and cut it into the contour of the yoga mat by laser or die punching, and polish the edge of the cut yoga mat.

[0032] Preparation of the A-side coil: plasticize natural rubber → mix with the A-side special color masterbatch → foam and form integrally with the fine cloth through a continuous compounding device → wind and temporarily store.

[0033] Preparation of the B-side coil: plasticize natural rubber → mix with the B-side special color masterbatch → foam and form integrally with the fine cloth through a continuous compounding device → wind and temporarily store.

[0034] Differentiated design: Different color masterbatch formulas for the A / B sides to achieve differences in double-sided color, hardness or texture.

[0035] Hot pressing and compounding: Continuously compound the A / B surface coils through a hot pressing roller, controlling the temperature (example: 120 - 150 °C) and pressure (example: 5 - 10 MPa) to form a stable bond between the double-sided rubber layers through the intermediate fine cloth.

[0036] Cutting and blanking: After compounding, cut the coil according to the preset length → Laser / die blanking into the outline of the yoga mat.

[0037] Integral foaming and compounding: Embed the fine cloth into the rubber layer during the foaming stage to enhance the structural strength and tear resistance.

[0038] Continuous production: Directly compound the A / B surfaces after synchronous preparation, reducing the intermediate storage link and increasing the efficiency by more than 20%.

[0039] Environmental protection: Use natural rubber and non-toxic color masterbatch throughout the process, without solvent addition.

[0040] It is worth mentioning that for the yoga mat produced by the present invention, the A-side rubber layer (thickness 2 - 4 mm, hardness 40 - 50 Shore A); the B-side rubber layer (thickness 2 - 4 mm, hardness 50 - 60 Shore A); the intermediate fine cloth reinforcement layer (thickness 0.2 - 0.5 mm); among them, the surface porosity of the A side and the B side is 30 - 50%, and the pore diameter is 0.1 - 0.5 mm.

[0041] Example 1: Basic production process

[0042] Preparation of A-side coil

[0043] - Plasticization: Plasticize natural rubber (Malaysian SMR20 standard rubber) in an open mill at 80 °C for 15 minutes;

[0044] - Mixing: Add 3% green water-based color masterbatch (containing phthalocyanine green pigment), and mix in a Banbury mixer for 20 minutes until uniform;

[0045] - Integral foaming: Feed the mixed rubber through an extruder and polyester fine cloth (grammage 80 g / ㎡, plasma-treated) into a foaming furnace, controlling the temperature in sections (preheating section 165 °C, foaming section 185 °C, shaping section 155 °C), and the foaming time is 6 minutes to form the A-side coil (thickness 3 mm, porosity 40%).

[0046] Preparation of B-side coil

[0047] - Plasticization and mixing: The same as the A-side process, using 5% blue water-based color masterbatch (containing cobalt blue pigment), and adding 2% hardness modifier (white carbon black);

[0048] - Foaming parameters: Raise the temperature of the foaming furnace to 190 °C and extend the foaming time to 7 minutes to obtain the B-side coil (thickness 3.2 mm, porosity 35%).

[0049] Compound and Molding

[0050] - Hot Press Lamination: The A / B surface coils are preheated to 130 °C and laminated by a double-roll hot press (pressure 8 MPa, micro-convex pattern depth on the roll surface 0.2 mm), with a linear speed of 2 m / min;

[0051] - Laser Cutting: A 400W CO2 laser is used, with a cutting speed of 15 mm / s, and cut into a standard size of 183 cm × 61 cm;

[0052] - Edge Treatment: A belt sander is used to remove burrs, with the precision controlled within ±0.3 mm.

[0053] Test Results:

[0054] Interlayer Peel Strength: 18 N / cm (standard of GB / T 2791-1995);

[0055] Rebound Rate: 88% (test of ASTM D3574);

[0056] VOC Emission: Benzene substances not detected (GC-MS detection limit 0.01 ppm).

[0057] Example 2: High Wear-Resistant Yoga Mat

[0058] Process Adjustment:

[0059] - The fine cloth is replaced with an aramid fiber woven fabric (gram weight 100 g / ㎡);

[0060] - The hot press temperature is increased to 145 °C, and the pressure is 10 MPa;

[0061] Performance Comparison:

[0062] - Wear Resistance: After 10,000 Martindale tests, the mass loss ≤ 1% (the loss of ordinary products is 3%);

[0063] - Tear Resistance Strength: 25 kN / m (a 50% increase).

[0064] Experimental Design

[0065] Test Samples:

[0066] Example 1 of the present invention (double-sided composite integral foaming process);

[0067] Control Example 1: Traditional single-layer natural rubber foamed yoga mat (without fine cloth reinforcement layer);

[0068] Control Example 2: Glue-bonded double-sided yoga mat (A / B surfaces are separately foamed and then bonded by PU glue, with a fine cloth layer);

[0069] Test Standards:

[0070] Peeling strength: GB / T 2791-1995 (Testing of adhesive peeling strength);

[0071] Abrasion resistance: GB / T 20991-2007 (Martindale method, 10,000 times of friction); Rebound rate: ASTM D3574 (Vertical rebound test);

[0072] VOC emission: ISO 16000-6 (Detection of volatile organic compounds);

[0073] Production efficiency: Output per unit time (sheets / hour);

[0074] The test results of the comparative experiment are as follows:

[0075] Performance indicators Example 1 Comparative Example 1 (single layer) Comparative Example 2 (glue bonding) Peel strength (N / cm) 18.2 Not applicable (single layer structure) 6.5 (interlayer glue failure) Abrasion resistance (mass loss %) 0.9 3.8 (severe surface wear) 2.1 (edge delamination and peeling) Rebound rate (%) 88 75 82 VOC emission (benzene ppm) Not detected (<0.01) 0.05 (foaming aid residue) 0.12 (glue solvent residue) Production efficiency (pieces / hour) 120 150 (simple process) 60 (requires glue curing time) Tear resistance (kN / m) 22.5 8.3 15.1 (fine cloth separated from the glue layer) Environmental friendliness Full water-based process, solvent-free Contains chemical foaming agent Contains organic solvent glue

[0076] As can be seen from the data in the above table, through integral foaming and compounding (fine cloth embedded in the rubber layer) in the present invention, the peeling strength is increased by 180% compared with Comparative Example 2 (adhesive bonding), completely solving the problem of interlayer separation. In Comparative Example 2, due to the decrease in bonding force after the glue ages, delamination is likely to occur at the edges after long-term use.

[0077] Double-sided differential design: The hardness difference between the A / B sides of Example 1 reaches 10 Shore A (A side 45, B side 55), while that of Comparative Example 1 is a single hardness (50 Shore A).

[0078] Improvement in abrasion resistance: The fine cloth reinforcing layer makes the abrasion resistance of Example 1 increase by 340% compared with Comparative Example 1.

[0079] VOC emission: In Example 1, water-based color masterbatch glue and glue-free process are adopted, and benzene substances are not detected, meeting the EU REACH regulations; Production efficiency: The continuous compounding process (120 sheets / hour) is increased by 100% compared with Comparative Example 2 (60 sheets / hour), and the labor cost is reduced by 40%.

[0080] The above are only the preferred embodiments of the present invention. All equivalent changes and modifications made according to the scope of the patent application of the present invention shall fall within the scope covered by the present invention.

Claims

1. A processing technology for a double-sided rubber yoga mat, characterized in that, The processing technology includes the following steps: Step S1: Prepare the natural rubber coil for side A and the natural rubber coil for side B respectively: Plasticize the natural rubber raw material, with the plasticizing temperature being 60 - 90 °C and the plasticizing time being 10 - 30 minutes; Step S2: Add color masterbatch into the plasticized natural rubber for mixing. Different color masterbatches are used for side A and side B respectively, and the addition amount of the color masterbatch is 1 - 5% of the total weight of the rubber; Step S3: Feed the mixed rubber compound and the fine cloth into the foaming furnace synchronously through a continuous compounding device, and foam and form at 160 - 200 °C to form a coil in which a rubber layer with a porous structure on the surface is compounded with the fine cloth; Step S4: Continuously compound the coil for side A and the coil for side B through a hot press roller. The hot press temperature is 120 - 150 °C and the pressure is 5 - 10 MPa, so that the rubber layer for side A and the rubber layer for side B are bonded through the intermediate fine cloth layer; Step S5: Cut the compounded coil according to a preset length, and cut it into the contour of a yoga mat by laser or die cutting, and polish the edge of the cut yoga mat.

2. The processing technology of a double-sided rubber yoga mat according to claim 1, wherein: The fine cloth in step S3 is a polyester fiber woven fabric with a gram weight of 50 - 120 g / ㎡. The fine cloth is pre-treated with plasma, and the surface roughness Ra is 1.2 - 2.5 μm.

3. A processing technology for a double-sided rubber yoga mat according to claim 1, characterized in that: The foaming furnace in step S3 has segmented temperature control. The foaming furnace is divided into a preheating section (160 - 170 °C), a foaming section (180 - 190 °C) and a shaping section (150 - 160 °C), and the total foaming time is 5 - 8 minutes.

4. The processing technology of a double-sided rubber yoga mat according to claim 1, characterized in that: The color masterbatch is an environment-friendly water-based color paste, and contains the following components by weight: natural rubber matrix: 100 parts; pigment particles: 5 - 15 parts; dispersant (fatty acid salt): 1 - 3 parts; antioxidant (type 1010): 0.5 - 1 part.

5. The processing technology of a double-sided rubber yoga mat according to claim 1, characterized in that: The surface of the hot press roller in step S4 is provided with micro-convex patterns, and the pattern depth is 0.1 - 0.3 mm, which is used to form anti-slip textures on the surface of the rubber layer during the compounding process.

6. A processing technology for a double-sided rubber yoga mat according to claim 1, characterized in that: The laser cutting in step S5 uses a CO2 laser, with a power of 200 - 500 W, a cutting speed of 10 - 20 mm / s, and a cutting seam width ≤ 0.1 mm.

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