A high-resilience wear-resistant floor mat and a method for making the same

Abstract

This invention discloses a highly elastic and wear-resistant floor mat and its preparation method, relating to the field of sports floor mat technology. The elastic and wear-resistant floor mat comprises a four-layer functional structure, from bottom to top: a high-resilience foam layer (1), a dimensionally stable layer (2), an intermediate transition foam layer (3), and a surface wear-resistant layer (4). The surface wear-resistant layer is composed of the following raw materials in parts by weight: 52-62 parts modified polyether-type thermoplastic polyurethane elastomer, 1-1.5 parts UV stabilizer UV-531, 3.5-5.5 parts modified nano-silica, 9-13 parts thermoplastic polyester elastomer, 0.4-0.6 parts antioxidant 1010, 0.6-0.9 parts zinc stearate, 2-3 parts maleic anhydride-grafted polyolefin elastomer, 0.5-0.7 parts trimethylolpropane triacrylate, and 0.6-1.2 parts perfluorooctanoate ethyl ester. The high-resilience foam layer of this mat accounts for 55%-70% of its thickness, providing ample cushioning. The surface wear-resistant layer is modified for weather resistance, abrasion resistance, and easy cleaning. It is manufactured through continuous extrusion without glue, making it environmentally friendly and suitable for the needs of peakball sports.

Description

Technical Field

[0001] This invention relates to the field of sports floor mat technology, specifically to a highly elastic and wear-resistant floor mat and its preparation method. Background Technology

[0002] With the increasing awareness of fitness among the general public, pickleball, as a sport that combines fun and competition, has rapidly gained popularity, leading to increasingly stringent performance requirements for dedicated sports flooring. Existing sports flooring often uses a single foam layer or a simple composite structure, making it difficult to balance elasticity, wear resistance, and dimensional stability, resulting in significant shortcomings.

[0003] Some playing mats use ordinary rubber or unmodified thermoplastic elastomer (TPE) as the base material. Although the cost is low, the elastic recovery rate is less than 80%. After long-term high-frequency impact, they are prone to collapse, causing the rebound height of the pickball to deviate by more than 10%, which affects the fairness of the game. In addition, the surface lacks targeted abrasion resistance modification. The Taber abrasion consumption often exceeds 15mg / 1000 revolutions, and obvious scratches appear after 1-2 years of use, shortening the service life.

[0004] In some cases, floor mats excessively increase the surface layer hardness (>95A) to improve wear resistance, but sacrifice the cushioning performance underfoot. This increases the stress on athletes' joints during exercise, making them more prone to sports injuries. At the same time, most floor mats do not contain stain-resistant additives, making it easy for sweat and beverage stains to adhere to the surface, which is difficult to clean. They also have poor weather resistance and are prone to aging and cracking after 600 hours of UV exposure when used outdoors, making them unsuitable for long-term outdoor use.

[0005] In terms of manufacturing process, traditional floor mats mostly adopt a layered bonding process, relying on adhesives to achieve interlayer connection. This not only has the problem of VOCs volatilization pollution, but also the interlayer peel strength is often lower than 3N / mm, which is prone to delamination and warping after long-term use. Some continuously extruded floor mats do not accurately match the thickness of each layer with the feeding rate, resulting in a high-resilience layer accounting for less than 50%, and the cushioning performance is substandard. They are difficult to meet the core requirements of "high-frequency impact, safe anti-slip, and long-term durability" in pickle ball sports. Therefore, there is an urgent need to develop a special elastic wear-resistant floor mat with optimized structure and materials and controllable process. Summary of the Invention

[0006] To address the shortcomings of existing technologies, this invention provides a highly elastic and wear-resistant floor mat and its preparation method, solving the problems of imbalance between elasticity and wear resistance, easy delamination between layers, poor weather resistance, and environmentally unfriendly processes in traditional floor mats.

[0007] To achieve the above objectives, the present invention provides the following technical solution:

[0008] A highly elastic and wear-resistant floor mat comprises a four-layer functional structure, consisting of a high-resilience foam layer, a dimensionally stable layer, an intermediate transition foam layer, and a surface wear-resistant layer, from bottom to top.

[0009] The surface wear-resistant layer is composed of the following raw materials in parts by weight: 52-62 parts modified polyether thermoplastic polyurethane elastomer (TPU), 1-1.5 parts UV stabilizer UV-531, 3.5-5.5 parts modified nano silica, 9-13 parts thermoplastic polyester elastomer (TPEE), 0.4-0.6 parts antioxidant 1010, 0.6-0.9 parts zinc stearate, 2-3 parts maleic anhydride grafted polyolefin elastomer, 0.5-0.7 parts trimethylolpropane triacrylate, and 0.6-1.2 parts perfluorooctanoate ethyl ester.

[0010] Furthermore, the thickness of the high-resilience foam layer accounts for 55%-70% of the total thickness of the mat, with a density of 0.5-0.9 g / cm³. This 55%-70% thickness ensures that the high-resilience foam layer dominates the cushioning performance, effectively absorbing the high-frequency impact force during pickle ball sports and reducing stress on the athlete's joints. 3 The density balances rebound efficiency and structural support, avoiding collapse caused by excessively low density and loss of elasticity caused by excessively high density, ensuring the stable rebound height of the peak ball, and improving the sports experience and the fairness of the competition.

[0011] Furthermore, the modified polyether-type thermoplastic polyurethane elastomer in the surface wear-resistant layer is prepared using the following specific steps:

[0012] A1. Dissolve polyether-type thermoplastic polyurethane elastomer particles in butyl acetate, stir at 300-400 r / min at 65-75℃ until completely dissolved, add polycaprolactone diol and dibutyltin dilaurate, and continue stirring at a constant temperature for 1 h; add 1,6-hexamethylene diisocyanate dropwise while stirring, raise the temperature to 85-95℃ and stir for 2.5-3.5 h; after the reaction is completed, remove the solvent by vacuum distillation at -0.08 MPa and 85℃, and dry the product under vacuum at 90℃ for 5-6 h to obtain the first modified polyether-type thermoplastic polyurethane elastomer;

[0013] After polyether-type thermoplastic polyurethane elastomer particles are dissolved in butyl acetate, the molecular chains are fully extended. The added polycaprolactone diol (containing hydroxyl groups at both ends) undergoes a nucleophilic addition reaction with the isocyanate groups in the subsequently added 1,6-hexamethylene diisocyanate under the action of dibutyltin dilaurate, forming urethane bonds. These bonds are ultimately inserted into the TPU hard segment structure in a block copolymer form, achieving chain extension and hardening effects. Heating to 85-95℃ can improve the reactivity, extend the hard segment length, and increase the hydrogen bond density, thereby improving the elastomer's resilience and compression fatigue resistance. Vacuum distillation removes the butyl acetate solvent, preventing residual solvent from affecting the molecular chain bonding stability and laying the foundation for subsequent modification.

[0014] A2. The first-modified polyether-type thermoplastic polyurethane elastomer was pulverized to 100-120 mesh and added to N,N-dimethylacetamide for ultrasonic dispersion for 40 min; isophorone diisocyanate and trimethylolpropane were added, and the mixture was stirred at 70-80℃ and 300-400 r / min for 3-4 h; after the reaction was completed, the reaction solution was poured into deionized water to precipitate, and the solid was filtered and dried at 80℃ for 6 h to obtain the second-modified polyether-type thermoplastic polyurethane elastomer.

[0015] The modified elastomer was pulverized to increase the particle surface area. After adding N,N-dimethylacetamide, it was uniformly suspended by ultrasonic dispersion. Trimethylolpropane first reacted with excess isophorone diisocyanate to generate a three-arm isocyanate-terminated prepolymer. The reaction temperature of 70-80℃ promoted further reaction between the prepolymer and residual amine or hydroxyl groups on the elastomer molecular chain, constructing a mildly three-dimensional cross-linked network and reducing unreacted groups. After the reaction, deionized water was added. Utilizing the difference in solubility between water and N,N-dimethylacetamide, and the insolubility of the elastomer in water, the modified elastomer rapidly precipitated, achieving product separation and purification, and further improving the mechanical strength and dimensional stability of the elastomer.

[0016] A3. Dissolve the second modified polyether thermoplastic polyurethane elastomer in toluene and heat it to 110-120℃ under nitrogen protection; add silane coupling agent KH-570 and dicumyl peroxide, and stir the reaction at 400-500 r / min for 30-40 min; after the reaction is completed, remove the solvent by vacuum distillation at -0.08 MPa and 85℃, and then dry it under vacuum at 100℃ for 7 h to obtain the modified polyether thermoplastic polyurethane elastomer.

[0017] After the modified elastomer is dissolved in toluene in the second step, nitrogen protection prevents the elastomer molecular chains from being oxidized at high temperatures. Heating to 110-120℃ maintains suitable reactivity in the system, and the thermal decomposition of dicumyl peroxide generates free radicals. These free radicals preferentially initiate free radical polymerization of the propylene groups in the silane coupling agent KH-570, generating oligomeric silanes. Simultaneously, the oligomeric silanes undergo a covalent grafting reaction with the TPU backbone, introducing the siloxane groups of KH-570 into the elastomer side chains. Subsequent vacuum distillation removes toluene, and the siloxane groups can act as active sites, forming chemical bridges with the surface groups of modified nano-silica, ultimately yielding a modified elastomer with high resilience, high wear resistance, and good compatibility.

[0018] Furthermore, the ratio of polyether-type thermoplastic polyurethane elastomer particles, butyl acetate, polycaprolactone diol, dibutyltin dilaurate, and 1,6-hexamethylene diisocyanate in A1 is 1000g: 280-320ml: 90-110g: 2-3g: 30-40g.

[0019] Furthermore, the ratio of the first modified polyether thermoplastic polyurethane elastomer, N,N-dimethylacetamide, isophorone diisocyanate, and trimethylolpropane in A2 is 1000g:300-350ml:45-55g:12-15g.

[0020] Furthermore, the ratio of the second modified polyether thermoplastic polyurethane elastomer, toluene, silane coupling agent KH-570, and dicumyl peroxide in A3 is 1000g: 250-280ml: 25-30ml: 6-8g.

[0021] Furthermore, the modified nano-silica in the surface wear-resistant layer is prepared using the following specific steps:

[0022] B1. Add nano-silica to an ethanol-water solution with a volume ratio of 4:1 and disperse ultrasonically for 30 min; adjust the pH to 4-5 with acetic acid, add silane coupling agent KH-590, and stir at 60-70℃ and 200-300 r / min for 3-3.5 h; after the reaction is completed, centrifuge to separate the precipitate, wash the precipitate with ethanol 2-3 times, and then vacuum dry at 70℃ for 4 h to obtain the first modified nano-silica;

[0023] The surface of nano-silica is rich in hydroxyl groups. In an ethanol-water solution with a volume ratio of 4:1, ethanol can reduce the surface tension of the system. Combined with ultrasonic dispersion, this ensures uniform dispersion of nano-silica particles and reduces agglomeration. Acetic acid adjusts the pH to 4-5, which can cause the siloxane groups in the silane coupling agent KH-590 to undergo a hydrolysis reaction to generate silanol groups. The hydrolyzed silanol groups of KH-590 can undergo a dehydration condensation reaction with the hydroxyl groups on the surface of nano-silica to form Si-O-Si covalent bonds, allowing KH-590 to be grafted onto the surface of nano-silica. The sulfur-containing group at the other end of KH-590 is an organic hydrophobic group that can replace the hydrophilic hydroxyl groups on the surface of nano-silica, reducing its surface energy and improving its compatibility with organic substrates. Centrifugation and ethanol washing can remove ungrafted KH-590, ensuring uniform modification.

[0024] B2. Add the first-modified nano-silica to deionized water and disperse at 1200 r / min for 20 min. Slowly add nitrile latex, heat to 55-60℃, and pre-disperse at 800-1000 r / min for 30 min. Add sulfur, zinc dithiocarbamate, and zinc oxide in sequence, and stir evenly at 600-800 r / min. Then add fumed nano-silica, stir at 500 r / min for 10 min, and spray dry. The inlet air temperature is 130℃, the outlet air temperature is 45-50℃, the feed rate is 15-20 ml / min, and the material stays in the high-temperature inlet air zone for 3-5 seconds to obtain the second-modified nano-silica.

[0025] After the first modification, the nano-silica was added to deionized water and then dispersed at a high speed of 1200 r / min to further break up the residual micro-agglomerates. The cyano groups in the nitrile latex molecular chain and the sulfur-containing groups of KH-590 on the surface of the nano-silica produced a polar interaction, forming a uniform and dense latex coating layer on the surface of the nano-silica. Heating to 55-60℃ can improve the fluidity of the latex molecular chain and promote the stable molding of the coating layer. The added sulfur, zinc dithiocarbamate and zinc oxide can initiate the pre-vulcanization of the nitrile latex molecular chain and enhance the mechanical strength of the coating layer. Because of its smaller particle size and larger specific surface area, fumed nano-silica can physically fill the gaps between the first-modified nano-silica particles, reducing the thermal bridging effect. During spray drying, the 130°C high-temperature air intake allows for rapid evaporation of moisture, while the 45-50°C outlet air temperature prevents the coating layer from overheating and aging. The short residence time of 3-5 seconds allows for rapid shaping, preventing secondary agglomeration of the nano-silica particles. Ultimately, a second-modified nano-silica with uniform coating and excellent dispersibility is obtained.

[0026] B3. Add the second modified nano-silica to acetone and ultrasonically disperse for 35 min; add antioxidant 3052 and benzophenone, irradiate with 365 nm ultraviolet light under nitrogen protection, and stir at 50-60℃ and 200-300 r / min for 3-4 h; after the reaction is completed, the vacuum degree is -0.08 MPa, the solvent is removed by vacuum distillation at 65℃, and then dried at 90℃ for 5 h to obtain modified nano-silica.

[0027] After the second modification of nano-silica is combined with acetone, ultrasonic dispersion ensures uniform particle suspension. Acetone acts only as a solvent for dispersion and does not react with the nano-silica surface coating. Under 365nm ultraviolet light irradiation, benzophenone preferentially abstracts allyl hydrogen from the nitrile latex coating molecular chain, generating NBR macromolecular free radicals. These macromolecular free radicals have a long lifetime and can further couple or abstract hydrogen with antioxidant 3052 and benzophenone, achieving photografting of antioxidant 3052 and benzophenone onto the nano-silica surface. Nitrogen protection prevents oxygen quenching of free radicals during the reaction, ensuring a complete grafting reaction. A reaction temperature of 50-60℃ increases molecular chain activity and accelerates the grafting reaction. After vacuum distillation to remove acetone, antioxidant 3052 captures free radicals generated during the use of the floor mat, delaying aging, while benzophenone absorbs ultraviolet light, reducing UV damage to the substrate. Ultimately, this endows nano-silica with dual antioxidant and UV-resistant functions, improving the weather resistance of the floor mat.

[0028] Furthermore, the ratio of nano-silica, ethanol aqueous solution, and silane coupling agent KH-590 in B1 is 500g: 180-220ml: 20-25ml.

[0029] Furthermore, the ratio of the first modified nano-silica, deionized water, nitrile latex, sulfur, zinc dithiocarbamate, zinc oxide, and fumed nano-silica in B2 is 500g: 200-230ml: 150-180g: 2.0-2.5g: 3-4g: 5-7g: 11-13g.

[0030] Furthermore, the ratio of the second modified nano-silica, acetone, antioxidant 3052, and benzophenone in B3 is 500g: 200-240ml: 15-20g: 4-6g.

[0031] Furthermore, the method for preparing the surface wear-resistant layer material includes the following steps:

[0032] C1. Place the modified polyether-type thermoplastic polyurethane elastomer in a vacuum drying oven and dry at 80-85℃ for 4-5 hours to remove moisture from the modified elastomer and avoid squeezing out air bubbles; place the modified nano-silica in an oven and dry at 60-65℃ for 2-3 hours to prevent agglomeration; mix the UV stabilizer UV-531 and ethyl perfluorooctanoate and stir at 50-55℃ and 300-400r / min for 10-15 minutes to prepare a uniform mixture;

[0033] C2. First, add the pretreated modified polyether-type thermoplastic polyurethane elastomer and thermoplastic polyester elastomer to the high-speed mixer. Stir at 600-700 rpm, mixing the elastomer and polyester at a low speed to avoid splashing. Heat to 70-75℃ and mix for 5 minutes. Then add the pretreated modified nano-silica and maleic anhydride-grafted polyolefin elastomer. Maintain the temperature at 70-75℃ and increase the speed to 800-900 rpm, mixing for 8-10 minutes to promote the dispersion of the nanofillers. Add antioxidants... Add agent 1010, zinc stearate, and trimethylolpropane triacrylate. Reduce the speed to 600 r / min and mix for 3-5 minutes. Reduce the speed to prevent the additives from becoming ineffective. Slowly add the pretreated UV stabilizer and ethyl perfluorooctanoate mixture, maintaining a temperature of 70-75°C to ensure the material softens without melting. Mix at 800 r / min for 5-6 minutes until the material is free of obvious lumps and has a uniform color. This ensures uniform mixing of all components, avoids uneven surface wear-resistant layer performance caused by lumps, and guarantees stable wear resistance, weather resistance, and other functions.

[0034] C3. Set the barrel temperature of the twin-screw extruder as follows: Zone 1 170-180℃, Zone 2 180-190℃, Zone 3 190-200℃, Zone 4 200-210℃, and the die head temperature 195-205℃; screw speed: 200-220 r / min, and feed rate: 20-25 kg / h; feed the high-speed mixed material into the twin-screw extruder and melt-blend it at the above temperature and speed; the molten material is extruded through the die head into strips with a diameter of 3-4 mm, and immediately cooled to below 40℃ in a 20-25℃ water cooling tank; the cooled strips are then cut into granules with a length of 3-4 mm by a pelletizer and dried in an 80℃ oven for 2-3 hours to obtain the surface wear-resistant layer material.

[0035] A method for preparing a highly elastic and wear-resistant floor mat includes the following steps:

[0036] S1. Preparation of high-resilience foam layer material: Add 80-90 parts of polyether-type thermoplastic polyurethane elastomer particles, 5-6 parts of polyethylene glycol, and 0.1-0.2 parts of dibutyltin dilaurate to a high-speed mixer and stir at 600-700 r / min for 10 min until uniformly mixed; transfer to an internal mixer, set the temperature to 160-165℃, the rotor speed to 40-50 r / min, and internally mix for 3 min. After the material melts, add 2-3 parts of azodicarbonamide and 0.2-0.4 parts of antioxidant 168, and continue internal mixing for 2 min to obtain the high-resilience foam layer premix.

[0037] S2. Preparation of intermediate transition foam layer material: Add 70-80 parts of polyether-type thermoplastic polyurethane elastomer particles, 4-5 parts of isophorone diisocyanate, and 0.3-0.5 parts of dicumyl peroxide to a high-speed mixer and stir at 500-600 r / min for 10 min; transfer to an internal mixer, set the temperature to 160-165℃, the rotor speed to 45-55 r / min, and mix for 2 min; then add 1-1.5 parts of silane coupling agent KH-550 and 10-15 parts of thermoplastic polyester elastomer, raise the temperature to 175-180℃, and continue mixing at 50-60 r / min for 3 min; finally add 1-2 parts of sodium bicarbonate and continue mixing for 1 min to obtain the transition foam layer premix.

[0038] S3. Pretreatment of dimensional stabilization layer: Immerse the nylon 66 mesh fabric in an ethanol aqueous solution with a volume ratio of 9:1 containing 1-2 wt% silane coupling agent KH-550 for 30 min at 60-65℃; after removal, dry at 80℃ for 2 h for later use; this step can introduce active groups on the surface of the fabric, improve its adhesion strength with the high resilience layer and transition layer, enhance the overall dimensional stability of the mat, and inhibit shrinkage and warping;

[0039] S4. Continuous extrusion molding: Start the three-layer co-extrusion extruder and the dimension stabilization layer guide roller device, add the surface wear-resistant layer material into the hopper of the single screw extruder, set the screw speed to 50-60 r / min, the barrel temperature to 185-195℃ in zone 1, 195-205℃ in zone 2, 205-210℃ in zone 3 and the die head temperature to 200-205℃, start the conveyor, and wait for the melt to be stably conveyed through the channel to the surface layer feed port of the three-layer co-extruder;

[0040] Add the intermediate transition foaming layer premix to the first twin-screw extruder, set the screw speed to 70-80 r / min, the barrel temperature to 175-185℃ in zone 1, 185-195℃ in zone 2, 205-210℃ in zone 3, and the die head temperature to 190-195℃, start the conveyor, and wait for the melt to be stably conveyed through the channel to the transition layer feed port of the three-layer co-extruder;

[0041] Add the high-resilience foam layer premix to the second twin-screw extruder, set the screw speed to 65-75 r / min, the barrel temperature to 170-180℃ in zone 1, 180-190℃ in zone 2, 190-200℃ in zone 3, and the die head temperature to 185-190℃, start the conveyor, and wait for the melt to be stably conveyed through the channel to the high-resilience layer feed port of the three-layer co-extruder;

[0042] After the three layers of melt have stably entered the three-layer co-extruder, the dimensional stabilizing layer, preheated to 80-90℃, is synchronously introduced into the interlayer composite channel of the three-layer co-extruder through guide rollers with a tension of 50-80N / m, so that it is precisely positioned between the transition layer and the high-resilience layer melt. Each layer of melt enters a 1.5-2m wide forming die in the order of high-resilience layer, dimensional stabilizing layer, transition layer, and surface wear-resistant layer. When the melt flows into the die, a composite pressure of 5-8MPa is maintained. The interlayer thermal fusion bonding is achieved by utilizing the temperature of each layer of melt, and finally, an adhesive-free integrated floor mat blank is continuously extruded. Adhesive-free thermal fusion bonding can avoid VOC pollution, while improving interlayer peel strength, preventing delamination, achieving integrated molding, improving production efficiency and the structural integrity of the floor mat.

[0043] S5. The floor mat blank is placed in an oven at 190-210℃ with a wind speed of 2-3m / s for 3-5 minutes. Then, it is calibrated for flatness under a tension of 30-50N / m. Next, it is cooled to 25-30℃ using a three-stage temperature-controlled cooling roller assembly. Finally, it is cut as needed to obtain an elastic and wear-resistant floor mat. The three-stage cooling process avoids internal stress and warping caused by temperature differences; it achieves floor mat shaping, flattening, and cooling, ensuring the dimensional accuracy and appearance quality of the finished product, meeting usage and cutting requirements.

[0044] Furthermore, in S4, the gap between the mold lip of the forming mold is adjusted to 8-12mm according to the total thickness of the floor mat. Specifically, the thickness of the high-resilience foam layer corresponding to the mold cavity area is designed to be 4.4-8.4mm, the intermediate transition foam layer corresponding to the mold cavity area is designed to be 1.4-2.6mm, the surface wear-resistant layer corresponding to the mold cavity area is designed to be 0.8-1.8mm, and the dimensional stabilization layer corresponding to the mold cavity area is designed to be 0.2-0.6mm. The twin-screw feeding rate for the high-resilience layer is 25-30kg / h, the feeding rate for the transition layer is 16-21kg / h, and the feeding rate for the surface wear-resistant layer is 9-14kg / h. The mold cavity thickness is designed to match the function of each layer. The thicker high-resilience layer ensures cushioning, while the thinner surface layer ensures wear resistance without affecting the feel underfoot. The feeding rate is matched to the mold cavity thickness to ensure uniform melt filling in each layer, avoiding performance fluctuations in the floor mat due to uneven thickness or feeding imbalance, ensuring that each layer fully functions and achieving overall performance balance.

[0045] Furthermore, the cooling roller assembly in S5 employs a three-stage temperature control system: the first stage has a water temperature of 20-22℃, the second stage 22-24℃, and the third stage 24-25℃, ensuring uniform cooling of the floor mat. This three-stage gradient cooling avoids excessive temperature differences between the surface and interior of the floor mat, preventing warping and cracking caused by uneven thermal expansion and contraction. The gradual temperature increase from 20-25℃ allows for slow and uniform cooling of the floor mat, releasing internal stress, improving dimensional stability, ensuring the flatness of the finished product, and reducing the risk of deformation during subsequent use.

[0046] This invention provides a highly elastic and wear-resistant floor mat and its preparation method, which has the following beneficial effects:

[0047] 1. The floor mat of this invention adopts a four-layer functional gradient structure from bottom to top: a high-resilience foam layer, a dimensionally stable layer, an intermediate transition foam layer, and a surface wear-resistant layer. The high-resilience foam layer accounts for 55%-70% and its density is controlled between 0.5-0.9 g / cm³. 3 It provides ample cushioning for peak ball sports, effectively absorbing the impact during the sport and reducing the stress on athletes' joints; the intermediate transition foam layer enables the performance connection between the high-resilience layer and the surface wear-resistant layer, avoiding performance gaps, while the dimensional stability layer can inhibit the shrinkage and warping of the mat during long-term use, ensuring the overall structural stability of the mat, guaranteeing the stable rebound trajectory of the peak ball on the field surface, and improving the sports experience and the fairness of the competition.

[0048] 2. The wear-resistant layer of the mat surface uses modified polyether thermoplastic polyurethane elastomer as the core raw material, combined with modified nano silica to enhance wear resistance. At the same time, UV-531 anti-ultraviolet agent and antioxidant 1010 are added to improve weather resistance, which can effectively resist ultraviolet radiation and environmental aging, and prevent cracking and fading problems after long-term use. The addition of perfluorooctanoic acid ethyl ester also gives the surface excellent stain resistance. Sweat, beverage stains and other stains are easy to clean, eliminating the need for frequent deep maintenance, greatly reducing usage costs, extending the overall service life of the mat, and meeting the needs of long-term outdoor or high-frequency use scenarios.

[0049] 3. This invention uses a continuous extrusion molding process to allow the melt layers to converge within the mold under a composite pressure of 5-8 MPa, and to achieve thermal bonding using the temperature of the melt itself. This eliminates the need for adhesives, avoiding the potential harm to the environment and human body from the volatilization of VOCs in adhesives. It also significantly improves the interlayer bonding strength, effectively preventing problems such as interlayer peeling and edge curling during long-term stress, curling, or cleaning of the floor mat. This ensures the structural integrity of the floor mat during use and reduces the safety hazards caused by interlayer separation.

[0050] 4. The preparation of each layer of the mat has clearly defined key parameters such as raw material ratio, temperature, and rotation speed. For example, the high-speed mixing and staged speed and temperature control of the surface wear-resistant layer, and the precise matching of the feeding rate of each layer with the mold cavity during extrusion molding, can ensure that the thickness and performance of each layer are stable and controllable, avoiding product quality differences caused by parameter fluctuations during production. The continuous extrusion integrated molding process also simplifies the complex process of traditional layer bonding, reduces production links, improves production efficiency, and reduces energy consumption and material waste. It is more suitable for large-scale mass production and meets the market's batch demand for peak ball-specific mats. Attached Figure Description

[0051] Figure 1 This is a structural diagram of the floor mat of the present invention.

[0052] In the diagram: 1. High-resilience foam layer; 2. Dimensionally stable layer; 3. Intermediate transition foam layer; 4. Surface wear-resistant layer. Detailed Implementation

[0053] The technical solutions in the embodiments of the present invention will be clearly and completely described below. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0054] Example 1: Preparation of an elastic and wear-resistant floor mat. The specific preparation steps are as follows:

[0055] S1. Preparation of high-resilience foam layer material: Add 80 parts of polyether-type thermoplastic polyurethane elastomer particles, 5 parts of polyethylene glycol, and 0.1 parts of dibutyltin dilaurate to a high-speed mixer and stir at 600 r / min for 10 min until uniformly mixed; transfer to an internal mixer, set the temperature to 160℃, the rotor speed to 40-50 r / min, and internally mix for 3 min. After the material melts, add 2 parts of azodicarbonamide and 0.2 parts of antioxidant 168, and continue internal mixing for 2 min to obtain the high-resilience foam layer premix.

[0056] S2. Preparation of intermediate transition foam layer material: 70 parts of polyether-type thermoplastic polyurethane elastomer particles, 4 parts of isophorone diisocyanate, and 0.3 parts of dicumyl peroxide were added to a high-speed mixer and stirred at 500 r / min for 10 min; then transferred to an internal mixer, set the temperature to 160℃, the rotor speed to 45 r / min, and internally mixed for 2 min; subsequently, 1 part of silane coupling agent KH-550 and 10 parts of thermoplastic polyester elastomer were added, the temperature was raised to 175℃, and the rotor speed was maintained at 50 r / min for 3 min; finally, 1 part of sodium bicarbonate was added, and internal mixing was continued for 1 min to obtain the transition foam layer premix;

[0057] S3. Pretreatment of the size stabilizing layer: Immerse the nylon 66 mesh fabric in an aqueous solution of ethanol at a volume ratio of 9:1 containing 1 wt% silane coupling agent KH-550, and soak at 60°C for 30 min; after removal, dry at 80°C for 2 h for later use.

[0058] S4. Continuous extrusion molding: Start the three-layer co-extrusion extruder and the dimension stabilization layer guide roller device, add the surface wear-resistant layer material prepared in Example 4 into the hopper of the single screw extruder, set the screw speed to 50 r / min, the barrel temperature to 185℃ in zone 1, 195℃ in zone 2, 205℃ in zone 3 and 200℃ in the die head, the feeding rate to 9 kg / h, start the conveying, and wait for the melt to be stably conveyed to the surface layer feed port of the three-layer co-extruder through the channel;

[0059] Add the intermediate transition foaming layer premix to the first twin-screw extruder, set the screw speed to 70 r / min, the barrel temperature to 175℃ in zone 1, 185℃ in zone 2, 205℃ in zone 3 and the die head temperature to 190℃, the feeding rate to 16 kg / h, start the conveyor, and wait for the melt to be stably conveyed through the channel to the transition layer feed port of the three-layer co-extruder.

[0060] Add the high-resilience foam layer premix to the second twin-screw extruder, set the screw speed to 65 r / min, the barrel temperature to 170℃ in zone 1, 180℃ in zone 2, 190℃ in zone 3 and the die head temperature to 185℃, the feeding rate to 25 kg / h, start the conveyor, and wait for the melt to be stably conveyed through the channel to the high-resilience layer feed port of the three-layer co-extruder.

[0061] Simultaneously, the die lip gap of the molding die is adjusted to 8mm according to the total thickness of the floor mat. The high-resilience foam layer is designed to have a thickness of 4.4mm in the mold cavity area, the intermediate transition foam layer to 1.4mm, the surface wear-resistant layer to 0.8mm, and the dimensional stabilizing layer to 0.2mm. After the melt of all three layers has stably entered the three-layer co-extrusion machine, the dimensional stabilizing layer, preheated to 80℃, is passed through guide rollers with a tension of 50N / m. The process involves introducing an interlayer composite channel into a three-layer co-extrusion machine, precisely positioning it between the transition layer and the high-resilience layer melt. Each layer melt enters a 1.5m wide forming die in the order of high-resilience layer, dimensionally stable layer, transition layer, and surface wear-resistant layer. When the melt flows into the die, a composite pressure of 5MPa is maintained. The interlayer thermal fusion bonding is achieved by utilizing the temperature of each layer melt itself. Finally, an integrated floor mat blank without adhesive is continuously extruded from bottom to top, consisting of a high-resilience foam layer, a dimensionally stable layer, an intermediate transition foam layer, and a surface wear-resistant layer.

[0062] S5. The floor mat blank is sent into a 190℃ oven with a wind speed of 2m / s and kept at that temperature for 3 minutes. Then, the flatness is calibrated by a tension of 30N / m. After that, it is cooled to 25℃ by a three-stage temperature-controlled cooling roller group and cut as needed to obtain an elastic and wear-resistant floor mat.

[0063] Example 2: Preparation of an elastic and wear-resistant floor mat. The specific preparation steps are as follows:

[0064] S1. Preparation of high-resilience foam layer material: 90 parts of polyether-type thermoplastic polyurethane elastomer particles, 6 parts of polyethylene glycol, and 0.2 parts of dibutyltin dilaurate were added to a high-speed mixer and stirred at 700 r / min for 10 min until uniformly mixed. The mixture was then transferred to an internal mixer, and the temperature was set at 165℃ and the rotor speed at 50 r / min for 3 min. After the material melted, 3 parts of azodicarbonamide and 0.4 parts of antioxidant 168 were added, and the mixture was continued to be internally mixed for 2 min to obtain the high-resilience foam layer premix.

[0065] S2. Preparation of intermediate transition foam layer material: 80 parts of polyether-type thermoplastic polyurethane elastomer particles, 5 parts of isophorone diisocyanate, and 0.5 parts of dicumyl peroxide were added to a high-speed mixer and stirred at 600 r / min for 10 min; then transferred to an internal mixer, set the temperature to 165℃, the rotor speed to 55 r / min, and internally mixed for 2 min; subsequently, 1.5 parts of silane coupling agent KH-550 and 15 parts of thermoplastic polyester elastomer were added, the temperature was raised to 180℃, and the rotor speed was maintained at 60 r / min for 3 min; finally, 2 parts of sodium bicarbonate were added, and internal mixing was continued for 1 min to obtain the transition foam layer premix;

[0066] S3. Pretreatment of the size stabilizing layer: Immerse the nylon 66 mesh fabric in an aqueous solution of ethanol at a volume ratio of 9:1 containing 2wt% silane coupling agent KH-550, and soak at 65℃ for 30 min; after removal, dry at 80℃ for 2 h for later use.

[0067] S4. Continuous extrusion molding: Start the three-layer co-extrusion extruder and the dimension stabilization layer guide roller device, add the surface wear-resistant layer material prepared in Example 4 into the hopper of the single screw extruder, set the screw speed to 60 r / min, the barrel temperature to 195℃ in zone 1, 205℃ in zone 2, 210℃ in zone 3 and 205℃ in the die head, and the feeding rate to 14 kg / h. Start the conveying process and wait for the melt to be stably conveyed through the channel to the surface layer feed port of the three-layer co-extruder.

[0068] Add the intermediate transition foaming layer premix to the first twin-screw extruder, set the screw speed to 80 r / min, the barrel temperature to 185℃ in zone 1, 195℃ in zone 2, 210℃ in zone 3 and the die head temperature to 195℃, the feeding rate to 21 kg / h, start the conveyor, and wait for the melt to be stably conveyed through the channel to the transition layer feed port of the three-layer co-extruder.

[0069] Add the high-resilience foam layer premix to the second twin-screw extruder, set the screw speed to 75 r / min, the barrel temperature to 180℃ in zone 1, 190℃ in zone 2, 200℃ in zone 3 and the die head temperature to 190℃, the feeding rate to 30 kg / h, start the conveyor, and wait for the melt to be stably conveyed through the channel to the high-resilience layer feed port of the three-layer co-extruder.

[0070] Simultaneously, the die lip gap of the molding die is adjusted to 12mm according to the total thickness of the floor mat. The high-resilience foam layer is designed to have a thickness of 8.4mm in the mold cavity area, the intermediate transition foam layer to 2.6mm, the surface wear-resistant layer to 1.8mm, and the dimensional stabilizing layer to 0.6mm. After the melt of all three layers has stably entered the three-layer co-extrusion machine, the dimensional stabilizing layer, preheated to 90℃, is passed through guide rollers with a tension of 80N / m. The interlayer composite channel of the three-layer co-extrusion machine is introduced simultaneously, so that it is precisely positioned between the transition layer and the high resilience layer melt. Each layer melt enters the 2m wide forming die in the order of high resilience layer, dimensional stability layer, transition layer and surface wear-resistant layer. When the melt flows in the die, a composite pressure of 8MPa is maintained. The interlayer thermal fusion bonding is achieved by using the temperature of each layer melt itself. Finally, an integrated floor mat blank without adhesive is continuously extruded from bottom to top, consisting of high resilience foam layer, dimensional stability layer, intermediate transition foam layer and surface wear-resistant layer.

[0071] S5. The floor mat blank is sent into a 210℃ oven with a wind speed of 3m / s and kept at that temperature for 5 minutes. Then, the flatness is calibrated by a tension of 50N / m. After that, it is cooled to 30℃ by a three-stage temperature-controlled cooling roller group and cut as needed to obtain an elastic and wear-resistant floor mat.

[0072] Example 3: Preparation of an elastic and wear-resistant floor mat. The specific preparation steps are as follows:

[0073] S1. Preparation of high-resilience foam layer material: 85 parts of polyether-type thermoplastic polyurethane elastomer particles, 5 parts of polyethylene glycol, and 0.15 parts of dibutyltin dilaurate were added to a high-speed mixer and stirred at 650 r / min for 10 min until uniformly mixed. The mixture was then transferred to an internal mixer, and the temperature was set at 162℃ and the rotor speed at 45 r / min for 3 min. After the material melted, 2 parts of azodicarbonamide and 0.3 parts of antioxidant 168 were added, and the mixture was continued to be internally mixed for 2 min to obtain the high-resilience foam layer premix.

[0074] S2. Preparation of intermediate transition foam layer material: 75 parts of polyether-type thermoplastic polyurethane elastomer particles, 4 parts of isophorone diisocyanate, and 0.4 parts of dicumyl peroxide were added to a high-speed mixer and stirred at 550 r / min for 10 min; then transferred to an internal mixer, set the temperature to 162℃, the rotor speed to 50 r / min, and internally mixed for 2 min; subsequently, 1 part of silane coupling agent KH-550 and 12 parts of thermoplastic polyester elastomer were added, the temperature was raised to 177℃, and the rotor speed was maintained at 55 r / min for 3 min; finally, 1 part of sodium bicarbonate was added, and internal mixing was continued for 1 min to obtain the transition foam layer premix.

[0075] S3. Pretreatment of the size stabilizing layer: Immerse the nylon 66 mesh fabric in an ethanol aqueous solution containing 1.5wt% silane coupling agent KH-550 at a volume ratio of 9:1 and soak at 62℃ for 30 min; after removal, dry at 80℃ for 2 h for later use.

[0076] S4. Continuous extrusion molding: Start the three-layer co-extrusion extruder and the dimension stabilization layer guide roller device, add the surface wear-resistant layer material prepared in Example 4 into the hopper of the single screw extruder, set the screw speed to 55 r / min, the barrel temperature to 190℃ in zone 1, 200℃ in zone 2, 207℃ in zone 3 and 202℃ in the die head, the feeding rate to 12 kg / h, start the conveying, and wait for the melt to be stably conveyed to the surface layer feed port of the three-layer co-extruder through the channel;

[0077] Add the intermediate transition foaming layer premix to the first twin-screw extruder, set the screw speed to 75 r / min, the barrel temperature to 180℃ in zone 1, 190℃ in zone 2, 207℃ in zone 3 and the die head temperature to 192℃, the feeding rate to 18 kg / h, start the conveyor, and wait for the melt to be stably conveyed through the channel to the transition layer feed port of the three-layer co-extruder.

[0078] Add the high-resilience foam layer premix to the second twin-screw extruder, set the screw speed to 70 r / min, the barrel temperature to 175℃ in zone 1, 185℃ in zone 2, 195℃ in zone 3 and 187℃ in the die head, and the feeding rate to 27 kg / h. Start the conveyor and wait for the melt to be stably conveyed through the channel to the high-resilience layer feed port of the three-layer co-extruder.

[0079] Simultaneously, the die lip gap of the molding die is adjusted to 10mm according to the total thickness of the floor mat. The thickness of the high-resilience foam layer corresponding to the mold cavity area is designed to be 6.4mm, the thickness of the intermediate transition foam layer corresponding to the mold cavity area is designed to be 2mm, the thickness of the surface wear-resistant layer corresponding to the mold cavity area is designed to be 1.2mm, and the thickness of the dimensional stabilizing layer corresponding to the mold cavity area is designed to be 0.4mm. After the melt of the three layers has been stably fed into the three-layer co-extrusion machine, the dimensional stabilizing layer, which has been preheated to 85℃, is synchronously passed through the guide rollers with a tension of 65N / m. The interlayer composite channel of the three-layer co-extrusion machine is introduced to precisely position it between the transition layer and the high-resilience layer melt. Each layer melt enters the 1.7m wide forming die in the order of high-resilience layer, dimensional stabilization layer, transition layer, and surface wear-resistant layer. When the melt flows into the die, a composite pressure of 7MPa is maintained. The interlayer thermal fusion bonding is achieved by utilizing the temperature of each layer melt itself. Finally, an integrated floor mat blank without adhesive is continuously extruded from bottom to top, consisting of a high-resilience foam layer, a dimensional stabilization layer, an intermediate transition foam layer, and a surface wear-resistant layer.

[0080] S5. The floor mat blank is sent into a 200℃ oven with a wind speed of 2.5m / s and kept at that temperature for 4 minutes. Then, the flatness is calibrated by a tension of 40N / m. After that, it is cooled to 27℃ by a three-stage temperature-controlled cooling roller group and cut as needed to obtain an elastic and wear-resistant floor mat.

[0081] Example 4: Preparation of surface wear-resistant layer material. The specific preparation steps are as follows:

[0082] C1. The modified polyether thermoplastic polyurethane elastomer prepared in Example 6 was placed in a vacuum drying oven and dried at 80°C for 4 hours; the modified nano-silica prepared in Example 9 was placed in an oven and dried at 60°C for 2 hours; 1 part of UV stabilizer UV-531 and 0.6 parts of ethyl perfluorooctanoate were mixed and stirred at 50°C and 300 r / min for 10 minutes to prepare a uniform mixture.

[0083] C2. First, add 52 parts of pretreated modified polyether thermoplastic polyurethane elastomer and 9 parts of thermoplastic polyester elastomer to a high-speed mixer, stir at 600 r / min, heat to 70℃, and mix for 5 min; then add 3.5 parts of pretreated modified nano silica and 2 parts of maleic anhydride grafted polyolefin elastomer, maintain 70℃, increase the speed to 800 r / min, and mix for 8 min; add 0.4 parts of antioxidant 1010, 0.6 parts of zinc stearate, and 0.5 parts of trimethylolpropane triacrylate, reduce the speed to 600 r / min, and mix for 3 min; slowly add the pretreated UV stabilizer and perfluorooctanoic acid ethyl ester mixture, maintain 70℃, and mix at 800 r / min for 5 min until the material has no obvious lumps and the color is uniform;

[0084] C3. Set the barrel temperature of the twin-screw extruder as follows: Zone 1 170℃, Zone 2 180℃, Zone 3 190℃, Zone 4 200℃, and the die head temperature 195℃; screw speed: 200 r / min, feed rate: 20 kg / h; feed the high-speed mixed material into the twin-screw extruder and melt-blend it at the above temperature and speed; the molten material is extruded through the die head into strips with a diameter of 3 mm, and immediately cooled to below 40℃ in a 20℃ water cooling tank; the cooled strips are cut into granules with a length of 3 mm by a pelletizer, and then dried in an 80℃ oven for 2 hours to obtain the surface wear-resistant layer material.

[0085] Example 5: Preparation of surface wear-resistant layer material. The specific preparation steps are as follows:

[0086] C1. The modified polyether thermoplastic polyurethane elastomer prepared in Example 6 was placed in a vacuum drying oven and dried at 85°C for 5 hours; the modified nano-silica prepared in Example 9 was placed in an oven and dried at 65°C for 3 hours; 1.5 parts of UV stabilizer UV-531 and 1.2 parts of perfluorooctanoic acid ethyl ester were mixed and stirred at 55°C and 400 r / min for 15 minutes to prepare a uniform mixture.

[0087] C2. First, add 62 parts of pretreated modified polyether thermoplastic polyurethane elastomer and 13 parts of thermoplastic polyester elastomer to a high-speed mixer, stir at 700 r / min, heat to 75℃, and mix for 5 min; then add 5.5 parts of pretreated modified nano silica and 3 parts of maleic anhydride grafted polyolefin elastomer, maintain 75℃, increase the speed to 900 r / min, and mix for 10 min; add 0.6 parts of antioxidant 1010, 0.9 parts of zinc stearate, and 0.7 parts of trimethylolpropane triacrylate, reduce the speed to 600 r / min, and mix for 5 min; slowly add the pretreated UV stabilizer and perfluorooctanoic acid ethyl ester mixture, maintain 75℃, and mix at 800 r / min for 6 min, until the material has no obvious lumps and the color is uniform;

[0088] C3. Set the barrel temperature of the twin-screw extruder as follows: Zone 1 180℃, Zone 2 190℃, Zone 3 200℃, Zone 4 210℃, and the die head temperature 205℃; screw speed: 220 r / min, and feed rate: 25 kg / h; feed the high-speed mixed material into the twin-screw extruder and melt-blend it at the above temperature and speed; the molten material is extruded through the die head into strips with a diameter of 4 mm, and immediately cooled to below 40℃ in a 25℃ water cooling tank; the cooled strips are cut into 4 mm long granules by a pelletizer and dried in an 80℃ oven for 3 hours to obtain the surface wear-resistant layer material.

[0089] Example 6: Preparation of modified polyether-type thermoplastic polyurethane elastomer. The specific preparation steps are as follows:

[0090] A1. Dissolve 1000g of polyether-type thermoplastic polyurethane elastomer particles in 280ml of butyl acetate, stir at 65℃ and 300r / min until completely dissolved, add 90g of polycaprolactone diol and 2g of dibutyltin dilaurate, and continue stirring at a constant temperature for 1h; while stirring, add 30g of 1,6-hexamethylene diisocyanate dropwise, raise the temperature to 85℃ and stir for 2.5h; after the reaction is completed, remove the solvent by vacuum distillation under vacuum conditions of -0.08MPa and 85℃, and dry the product under vacuum at 90℃ for 5h to obtain the first modified polyether-type thermoplastic polyurethane elastomer;

[0091] A2. 1000g of the first-modified polyether thermoplastic polyurethane elastomer was pulverized to 100 mesh and added to 300ml of N,N-dimethylacetamide for ultrasonic dispersion for 40min; 45g of isophorone diisocyanate and 12g of trimethylolpropane were added, and the mixture was stirred at 70℃ and 300r / min for 3h; after the reaction was completed, the reaction solution was poured into deionized water to precipitate, and the solid was filtered and dried at 80℃ for 6h to obtain the second-modified polyether thermoplastic polyurethane elastomer.

[0092] A3. Dissolve 1000g of the second modified polyether thermoplastic polyurethane elastomer in 250ml of toluene, and heat to 110℃ under nitrogen protection; add 25ml of silane coupling agent KH-570 and 6g of dicumyl peroxide, and stir at 400r / min for 30min; after the reaction is completed, remove the solvent by vacuum distillation at -0.08MPa and 85℃, and then dry under vacuum at 100℃ for 7h to obtain the modified polyether thermoplastic polyurethane elastomer.

[0093] Example 7: Preparation of modified polyether-type thermoplastic polyurethane elastomer. The specific preparation steps are as follows:

[0094] A1. Dissolve 1000g of polyether-type thermoplastic polyurethane elastomer particles in 320ml of butyl acetate, stir at 75℃ and 400r / min until completely dissolved, add 110g of polycaprolactone diol and 3g of dibutyltin dilaurate, and continue stirring at a constant temperature for 1h; while stirring, add 40g of 1,6-hexamethylene diisocyanate dropwise, raise the temperature to 95℃ and stir for 3.5h; after the reaction is completed, remove the solvent by vacuum distillation under vacuum conditions of -0.08MPa and 85℃, and dry the product under vacuum at 90℃ for 6h to obtain the first modified polyether-type thermoplastic polyurethane elastomer;

[0095] A2. 1000g of the first-modified polyether thermoplastic polyurethane elastomer was pulverized to 120 mesh and added to 350ml of N,N-dimethylacetamide for ultrasonic dispersion for 40min; 55g of isophorone diisocyanate and 15g of trimethylolpropane were added, and the mixture was stirred at 80℃ and 400r / min for 4h; after the reaction was completed, the reaction solution was poured into deionized water to precipitate, and the solid was filtered and dried at 80℃ for 6h to obtain the second-modified polyether thermoplastic polyurethane elastomer.

[0096] A3. Dissolve 1000g of the second modified polyether thermoplastic polyurethane elastomer in 280ml of toluene, and heat to 120℃ under nitrogen protection; add 30ml of silane coupling agent KH-570 and 8g of dicumyl peroxide, and stir at 500r / min for 40min; after the reaction is completed, remove the solvent by vacuum distillation at -0.08MPa and 85℃, and then dry under vacuum at 100℃ for 7h to obtain the modified polyether thermoplastic polyurethane elastomer.

[0097] Example 8: Preparation of modified nano-silica. The specific preparation steps are as follows:

[0098] B1. Add 500g of nano-silica to 180ml of ethanol-water solution with a volume ratio of 4:1 and disperse by ultrasonication for 30min; adjust the pH to 4 with acetic acid, add 20ml of silane coupling agent KH-590, and stir at 60℃ and 200r / min for 3h; after the reaction is completed, centrifuge to separate the precipitate, wash it twice with ethanol, and then vacuum dry it at 70℃ for 4h to obtain the first modified nano-silica.

[0099] B2. Add 500g of the first-modified nano-silica to 200ml of deionized water and disperse at 1200r / min for 20min. Slowly add 150g of nitrile latex, heat to 55℃, and pre-disperse at 800r / min for 30min. Then add 2.0g of sulfur, 3g of zinc dithiocarbamate, and 5g of zinc oxide in sequence. Stir at 600r / min until uniform. Add 11g of fumed nano-silica and stir at 500r / min for 10min. Spray dry the material at an inlet air temperature of 130℃, an outlet air temperature of 45℃, and a feed rate of 15ml / min. The material stays in the high-temperature inlet air zone for 3s to obtain the second-modified nano-silica.

[0100] B3. Add 500g of the second-modified nano-silica to 200ml of acetone and ultrasonically disperse for 35min; add 15g of antioxidant 3052 and 4g of benzophenone, irradiate with 365nm ultraviolet light under nitrogen protection, and stir at 50℃ and 200r / min for 3h; after the reaction is completed, the vacuum degree is -0.08MPa, the solvent is removed by vacuum distillation at 65℃, and then dried at 90℃ for 5h to obtain modified nano-silica.

[0101] Example 9: Preparation of modified nano-silica. The specific preparation steps are as follows:

[0102] B1. Add 500g of nano-silica to 220ml of ethanol-water solution with a volume ratio of 4:1 and disperse by ultrasonication for 30min; adjust the pH to 5 with acetic acid, add 25ml of silane coupling agent KH-590, and stir at 70℃ and 300r / min for 3.5h; after the reaction is completed, centrifuge to separate the precipitate, wash the precipitate with ethanol 3 times, and then vacuum dry at 70℃ for 4h to obtain the first modified nano-silica.

[0103] B2. Add 500g of the first-modified nano-silica to 230ml of deionized water and disperse at 1200r / min for 20min. Slowly add 180g of nitrile latex, heat to 60℃, and pre-disperse at 1000r / min for 30min. Then add 2.5g of sulfur, 4g of zinc dithiocarbamate, and 7g of zinc oxide in sequence. Stir at 800r / min until uniform. Add 13g of fumed nano-silica and stir at 500r / min for 10min. Spray dry the material at an inlet air temperature of 130℃, an outlet air temperature of 50℃, and a feed rate of 20ml / min. The material stays in the high-temperature inlet air zone for 5s to obtain the second-modified nano-silica.

[0104] B3. Add 500g of the second-modified nano-silica to 240ml of acetone and ultrasonically disperse for 35min; add 20g of antioxidant 3052 and 6g of benzophenone, irradiate with 365nm ultraviolet light under nitrogen protection, and stir at 60℃ and 300r / min for 4h; after the reaction is completed, the vacuum degree is -0.08MPa, the solvent is removed by vacuum distillation at 65℃, and then dried at 90℃ for 5h to obtain modified nano-silica.

[0105] Comparative Example 1: An elastic and wear-resistant floor mat was prepared. The specific preparation steps are as follows:

[0106] The remaining steps remain unchanged, except that the modified polyether thermoplastic polyurethane elastomer prepared in Example 6 and used in the surface wear-resistant layer material of Example 4 are replaced with unmodified polyether thermoplastic polyurethane elastomer, which is used to prepare the elastic wear-resistant floor mat in Example 3.

[0107] Comparative Example 2: An elastic and wear-resistant floor mat was prepared. The specific preparation steps are as follows:

[0108] The remaining steps remain unchanged, except that the modified nano-silica prepared in Example 9, which was used in the surface wear-resistant layer material of Example 4, is replaced with unmodified nano-silica for use in the preparation of the elastic wear-resistant floor mat in Example 3.

[0109] Comparative Example 3: An elastic and wear-resistant floor mat was prepared. The specific preparation steps are as follows:

[0110] The remaining steps remain unchanged, except that the modified polyether thermoplastic polyurethane elastomer prepared in Example 6 used in the surface wear-resistant layer material of Example 4 is replaced with an unmodified polyether thermoplastic polyurethane elastomer, and the modified nano silica prepared in Example 9 is replaced with an unmodified nano silica, which is used to prepare the elastic wear-resistant floor mat in Example 3.

[0111] Performance testing

[0112] A 150mm × 150mm sample was cut from the finished floor mat, and surface defects were removed to obtain the test sample.

[0113] The elastic recovery rate test was performed with a compression of 50% of the original thickness, a holding time of 60 seconds, and a recovery time of 300 seconds after decompression.

[0114] Taber wear resistance test load: 1000g / wheel;

[0115] For the interlayer peel strength test, the peel speed was 100 mm / min, the clamping distance was 50 mm, and the average load of the stable section of 50 mm was taken.

[0116] UV-A340 UV aging resistance test lamp, 0.76 W·m -2@340nm, 8h of cyclic illumination (60℃ blackboard temperature) + 4h of condensation (50℃), for a total of 600h;

[0117] The stain resistance test was conducted using coffee as the contaminant. The cloth was cleaned with deionized water, and the surfaces were wiped back and forth five times at a pressure of 2 N / cm. 2 ;

[0118] For the Shore A hardness test, the distance between the test points should be ≥10mm and the distance from the edge should be ≥5mm. Take the median value of 5 points and the reading time should be 1s.

[0119] Based on the performance test results, the elastic wear-resistant mats prepared in Examples 1-3 exhibit excellent overall performance: the elastic recovery rate reaches 90%-96%, which can meet the cushioning and rebound requirements of pickle ball sports; the Taber abrasion loss is only 6.2-9.5 mg / 1000 revolutions, demonstrating outstanding abrasion resistance; the interlayer peel strength is 3.6-4.5 N / mm, indicating strong interlayer bonding; there is no significant change after 600 hours of ultraviolet aging, demonstrating good weather resistance; the stain resistance reaches level 1-2, making it easy to clean; and the Shore hardness is 80-83A, providing a comfortable feel underfoot without affecting the sports experience. The performance of Comparative Example 1 (without modified polyether thermoplastic polyurethane elastomer), Comparative Example 2 (without modified nano silica), and Comparative Example 3 (without any modified raw materials) all showed a significant decline. Specifically, the elastic recovery rate dropped to 82%-88%, the wear resistance increased to 11.8-14.2 mg / kJ, the interlaminar peel strength dropped to 2.8-3.3 N / mm, and the stain resistance was only level 2-4. Comparative Example 3 also showed slight cracking and fading. This fully demonstrates that the modified polyether thermoplastic polyurethane elastomer and modified nano silica in the surface wear-resistant layer are crucial for improving the overall performance of the floor mat.

[0120] The above description is merely an example and illustration of the present invention. Those skilled in the art can make various modifications or additions to the specific embodiments described, or use similar methods to replace them, as long as they do not deviate from the invention or exceed the scope defined in the claims, all of which should fall within the protection scope of the present invention.

Claims

1. A highly elastic and wear-resistant floor mat, characterized in that: The floor mat includes a four-layer functional structure, which from bottom to top are a high-resilience foam layer (1), a dimensionally stable layer (2), an intermediate transition foam layer (3), and a surface wear-resistant layer (4). The surface wear-resistant layer is composed of the following raw materials in parts by weight: 52-62 parts modified polyether thermoplastic polyurethane elastomer, 1-1.5 parts UV stabilizer UV-531, 3.5-5.5 parts modified nano silica, 9-13 parts thermoplastic polyester elastomer, 0.4-0.6 parts antioxidant 1010, 0.6-0.9 parts zinc stearate, 2-3 parts maleic anhydride grafted polyolefin elastomer, 0.5-0.7 parts trimethylolpropane triacrylate, and 0.6-1.2 parts perfluorooctanoate ethyl ester.

2. The highly elastic and wear-resistant floor mat according to claim 1, characterized in that: The thickness of the high-resilience foam layer accounts for 55%-70% of the total thickness of the mat, and its density is 0.5-0.9 g / cm³. 3 .

3. The highly elastic and wear-resistant floor mat according to claim 1, characterized in that: The modified polyether-type thermoplastic polyurethane elastomer in the surface wear-resistant layer is prepared using the following specific steps: A1. Dissolve polyether-type thermoplastic polyurethane elastomer particles in butyl acetate, stir at 300-400 r / min at 65-75℃ until completely dissolved, add polycaprolactone diol and dibutyltin dilaurate, and continue stirring at a constant temperature for 1 h; add 1,6-hexamethylene diisocyanate dropwise while stirring, raise the temperature to 85-95℃ and stir for 2.5-3.5 h; after the reaction is completed, remove the solvent by vacuum distillation at -0.08 MPa and 85℃, and dry the product under vacuum at 90℃ for 5-6 h to obtain the first modified polyether-type thermoplastic polyurethane elastomer; A2. The first-modified polyether-type thermoplastic polyurethane elastomer was pulverized to 100-120 mesh and added to N,N-dimethylacetamide for ultrasonic dispersion for 40 min; isophorone diisocyanate and trimethylolpropane were added, and the mixture was stirred at 70-80℃ and 300-400 r / min for 3-4 h; after the reaction was completed, the reaction solution was poured into deionized water to precipitate, and the solid was filtered and dried at 80℃ for 6 h to obtain the second-modified polyether-type thermoplastic polyurethane elastomer. A3. Dissolve the second modified polyether thermoplastic polyurethane elastomer in toluene and heat it to 110-120℃ under nitrogen protection; add silane coupling agent KH-570 and dicumyl peroxide, and stir the reaction at 400-500 r / min for 30-40 min; after the reaction is completed, remove the solvent by vacuum distillation at -0.08 MPa and 85℃, and then dry it under vacuum at 100℃ for 7 h to obtain the modified polyether thermoplastic polyurethane elastomer.

4. The highly elastic and wear-resistant floor mat according to claim 3, characterized in that: The ratio of polyether-type thermoplastic polyurethane elastomer particles, butyl acetate, polycaprolactone diol, dibutyltin dilaurate, and 1,6-hexamethylene diisocyanate in A1 is 1000g: 280-320ml: 90-110g: 2-3g: 30-40g. The ratio of the first modified polyether thermoplastic polyurethane elastomer, N,N-dimethylacetamide, isophorone diisocyanate, and trimethylolpropane in A2 is 1000g: 300-350ml: 45-55g: 12-15g. The ratio of the second modified polyether thermoplastic polyurethane elastomer, toluene, silane coupling agent KH-570, and dicumyl peroxide in A3 is 1000g: 250-280ml: 25-30ml: 6-8g.

5. The highly elastic and wear-resistant floor mat according to claim 1, characterized in that: The modified nano-silica in the surface wear-resistant layer is prepared by the following steps: B1. Add nano-silica to an ethanol-water solution with a volume ratio of 4:1 and disperse ultrasonically for 30 min; adjust the pH to 4-5 with acetic acid, add silane coupling agent KH-590, and stir at 60-70℃ and 200-300 r / min for 3-3.5 h; after the reaction is completed, centrifuge to separate the precipitate, wash the precipitate with ethanol 2-3 times, and then vacuum dry at 70℃ for 4 h to obtain the first modified nano-silica; B2. Add the first-modified nano-silica to deionized water and disperse at 1200 r / min for 20 min. Slowly add nitrile latex, heat to 55-60℃, and pre-disperse at 800-1000 r / min for 30 min. Add sulfur, zinc dithiocarbamate, and zinc oxide in sequence, and stir evenly at 600-800 r / min. Then add fumed nano-silica, stir at 500 r / min for 10 min, and spray dry. The inlet air temperature is 130℃, the outlet air temperature is 45-50℃, the feed rate is 15-20 ml / min, and the material stays in the high-temperature inlet air zone for 3-5 seconds to obtain the second-modified nano-silica. B3. Add the second modified nano-silica to acetone and ultrasonically disperse for 35 min; add antioxidant 3052 and benzophenone, irradiate with 365 nm ultraviolet light under nitrogen protection, and stir at 50-60℃ and 200-300 r / min for 3-4 h; after the reaction is completed, the vacuum degree is -0.08 MPa, the solvent is removed by vacuum distillation at 65℃, and then dried at 90℃ for 5 h to obtain modified nano-silica.

6. The highly elastic and wear-resistant floor mat according to claim 5, characterized in that: The ratio of nano-silica, ethanol aqueous solution, and silane coupling agent KH-590 in B1 is 500g: 180-220ml: 20-25ml; The ratio of the first modified nano-silica, deionized water, nitrile latex, sulfur, zinc dithiocarbamate, zinc oxide, and fumed nano-silica in B2 is 500g: 200-230ml: 150-180g: 2.0-2.5g: 3-4g: 5-7g: 11-13g; The ratio of the second modified nano-silica, acetone, antioxidant 3052, and benzophenone in B3 is 500g: 200-240ml: 15-20g: 4-6g.

7. The highly elastic and wear-resistant floor mat according to claim 1, characterized in that: The method for preparing the surface wear-resistant layer material includes the following steps: C1. Place the modified polyether-type thermoplastic polyurethane elastomer in a vacuum drying oven and dry at 80-85℃ for 4-5 hours; place the modified nano-silica in an oven and dry at 60-65℃ for 2-3 hours; mix the UV stabilizer UV-531 and ethyl perfluorooctanoate and stir at 50-55℃ and 300-400r / min for 10-15 minutes to prepare a uniform mixture. C2. First, add the pretreated modified polyether thermoplastic polyurethane elastomer and thermoplastic polyester elastomer to the high-speed mixer, stir at 600-700 r / min, heat to 70-75℃, and mix for 5 min; then add the pretreated modified nano silica and maleic anhydride grafted polyolefin elastomer, maintain 70-75℃, increase the speed to 800-900 r / min, and mix for 8-10 min; add antioxidant 1010, zinc stearate, and trimethylolpropane triacrylate, reduce the speed to 600 r / min, and mix for 3-5 min; slowly add the pretreated UV stabilizer and perfluorooctanoate mixture, maintain 70-75℃, speed 800 r / min, and mix for 5-6 min until the material has no obvious lumps and the color is uniform. C3. Set the barrel temperature of the twin-screw extruder as follows: Zone 1 170-180℃, Zone 2 180-190℃, Zone 3 190-200℃, Zone 4 200-210℃, and the die head temperature 195-205℃; screw speed: 200-220 r / min, and feed rate: 20-25 kg / h; feed the high-speed mixed material into the twin-screw extruder and melt-blend it at the above temperature and speed; the molten material is extruded through the die head into strips with a diameter of 3-4 mm, and immediately cooled to below 40℃ in a 20-25℃ water cooling tank; the cooled strips are then cut into granules with a length of 3-4 mm by a pelletizer and dried in an 80℃ oven for 2-3 hours to obtain the surface wear-resistant layer material.

8. A method for preparing a highly elastic and wear-resistant floor mat, characterized in that: Specifically, it includes the following steps: S1. Preparation of high-resilience foam layer material: Add 80-90 parts of polyether-type thermoplastic polyurethane elastomer particles, 5-6 parts of polyethylene glycol, and 0.1-0.2 parts of dibutyltin dilaurate to a high-speed mixer and stir at 600-700 r / min for 10 min until uniformly mixed; transfer to an internal mixer, set the temperature to 160-165℃, the rotor speed to 40-50 r / min, and internally mix for 3 min. After the material melts, add 2-3 parts of azodicarbonamide and 0.2-0.4 parts of antioxidant 168, and continue internal mixing for 2 min to obtain the high-resilience foam layer premix. S2. Preparation of intermediate transition foam layer material: Add 70-80 parts of polyether-type thermoplastic polyurethane elastomer particles, 4-5 parts of isophorone diisocyanate, and 0.3-0.5 parts of dicumyl peroxide to a high-speed mixer and stir at 500-600 r / min for 10 min; transfer to an internal mixer, set the temperature to 160-165℃, the rotor speed to 45-55 r / min, and mix for 2 min; then add 1-1.5 parts of silane coupling agent KH-550 and 10-15 parts of thermoplastic polyester elastomer, raise the temperature to 175-180℃, and continue mixing at 50-60 r / min for 3 min; finally add 1-2 parts of sodium bicarbonate and continue mixing for 1 min to obtain the transition foam layer premix. S3. Pretreatment of the size stabilizing layer: Immerse the nylon 66 mesh fabric in an ethanol aqueous solution containing 1-2 wt% silane coupling agent KH-550 at a volume ratio of 9:1 and soak at 60-65℃ for 30 min; after removal, dry at 80℃ for 2 h for later use. S4. Continuous extrusion molding: Start the three-layer co-extrusion extruder and the dimension stabilization layer guide roller device, add the surface wear-resistant layer material into the hopper of the single screw extruder, set the screw speed to 50-60 r / min, the barrel temperature to 185-195℃ in zone 1, 195-205℃ in zone 2, 205-210℃ in zone 3 and the die head temperature to 200-205℃, start the conveyor, and wait for the melt to be stably conveyed through the channel to the surface layer feed port of the three-layer co-extruder; Add the intermediate transition foaming layer premix to the first twin-screw extruder, set the screw speed to 70-80 r / min, the barrel temperature to 175-185℃ in zone 1, 185-195℃ in zone 2, 205-210℃ in zone 3, and the die head temperature to 190-195℃, start the conveyor, and wait for the melt to be stably conveyed through the channel to the transition layer feed port of the three-layer co-extruder; Add the high-resilience foam layer premix to the second twin-screw extruder, set the screw speed to 65-75 r / min, the barrel temperature to 170-180℃ in zone 1, 180-190℃ in zone 2, 190-200℃ in zone 3, and the die head temperature to 185-190℃, start the conveyor, and wait for the melt to be stably conveyed through the channel to the high-resilience layer feed port of the three-layer co-extruder; After the three layers of melt have been stably introduced into the three-layer co-extruder, the dimensional stabilizing layer, which has been preheated to 80-90℃, is synchronously introduced into the interlayer composite channel of the three-layer co-extruder through guide rollers with a tension of 50-80N / m, so that it is precisely positioned between the transition layer and the high-resilience layer melt. Each layer of melt enters the 1.5-2m wide forming die in the order of high-resilience layer, dimensional stabilizing layer, transition layer, and surface wear-resistant layer. When the melt flows into the die, a composite pressure of 5-8MPa is maintained. The interlayer thermal fusion bonding is achieved by utilizing the temperature of each layer of melt. Finally, an integrated floor mat blank without adhesive is continuously extruded. S5. The floor mat blank is sent into an oven at 190-210℃ with a wind speed of 2-3m / s and kept at that temperature for 3-5 minutes. Then, the flatness is calibrated by a tension of 30-50N / m. After that, it is cooled to 25-30℃ by a three-stage temperature-controlled cooling roller group and cut as needed to obtain an elastic and wear-resistant floor mat.

9. The method for preparing a highly elastic and wear-resistant floor mat according to claim 8, characterized in that: The gap between the mold lip of the forming mold in S4 is adjusted to 8-12mm according to the total thickness of the floor mat. The thickness of the high-resilience foam layer in the mold cavity area is designed to be 4.4-8.4mm, the thickness of the intermediate transition foam layer in the mold cavity area is designed to be 1.4-2.6mm, the thickness of the surface wear-resistant layer in the mold cavity area is designed to be 0.8-1.8mm, and the thickness of the dimensional stabilization layer in the mold cavity area is designed to be 0.2-0.6mm. The twin-screw feeding rate of the high-resilience layer is 25-30kg / h, the feeding rate of the transition layer is 16-21kg / h, and the feeding rate of the surface wear-resistant layer is 9-14kg / h.

10. The method for preparing a highly elastic and wear-resistant floor mat according to claim 8, characterized in that: The S5 cooling roller assembly adopts a three-stage temperature control: the first stage water temperature is 20-22℃, the second stage is 22-24℃, and the third stage is 24-25℃, to ensure uniform cooling of the floor mat.

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