High toughness break-resistant foamed composite cushion and process for making same

Abstract

This invention belongs to the field of chemical technology and discloses a high-toughness, fracture-resistant foamed composite mat and its processing technology. The high-toughness, fracture-resistant foamed composite mat and its processing technology include a mat body with a thickness of 3-15 mm, comprising two or more soft elastic foam layers; at least one reinforcing layer is disposed between adjacent soft elastic foam layers. This high-toughness, fracture-resistant foamed composite mat and its processing technology solve the core problems of insufficient toughness and easy breakage when bent in existing PU foamed yoga mats, crawling mats, and other similar products: through the structure of the PU foam layer and the reinforcing layer interlaced, the excellent toughness and tensile strength of the reinforcing layer are utilized to disperse the stress generated when the yoga mat is bent, avoiding cracking and breakage of the PU foam layer due to stress concentration, thus solving the problems mentioned in the background art.

Description

Technical Field

[0001] This invention relates to the technical field of chemical engineering, specifically to a high-toughness, fracture-resistant foamed composite pad and its processing technology. Background Technology

[0002] Continuous physical foaming materials (such as PU (polyurethane) foam, acrylic foam, etc.) have excellent elasticity and stable environmental performance, and are widely used in the sealing and cushioning fields of electronic products. However, there is a significant market gap in the field of 3-15mm thick living mats. Traditional one-piece molded foaming materials lack toughness and have poor flexural strength, making them prone to breakage, tearing, and damage after long-term use, failing to meet usage requirements. Currently, the industry still uses a large amount of materials with poor elasticity and insufficient environmental stability, such as TPE, XPE, and rubber. Existing technologies mostly involve surface lamination or coating treatments, which only improve surface properties and cannot improve overall toughness from the inside. Conventional multi-layer composites require adhesives, are prone to delamination, and are costly, making them difficult to scale up. There has long been a technical contradiction in this field: how to maintain high elasticity while improving toughness, how to achieve multi-layer composites without using adhesives, and how to avoid significantly increasing costs. Existing technologies cannot solve these problems simultaneously.

[0003] In view of the shortcomings of the existing technologies, there is an urgent need for a high-toughness, fracture-resistant foam composite mat and its processing technology that can significantly improve the toughness and strength of yoga mats, crawling mats and other similar products while retaining the high elasticity and environmental protection advantages of PU foam materials, avoid bending and breaking, and have a simple processing technology that is easy to industrialize. Summary of the Invention

[0004] The purpose of this invention is to provide a high-toughness, fracture-resistant foamed composite mat and its processing technology. This high-toughness, fracture-resistant foamed composite mat and its processing technology solve the problems mentioned in the background art. It is a multi-layer foamed composite mat with high elasticity, high toughness, fracture resistance, and tear resistance, and is suitable for yoga mats, crawling mats, car floor mats, table mats and other daily necessities.

[0005] To achieve the above objectives, the present invention provides the following technical solution: a high-toughness, fracture-resistant foamed composite pad, comprising a pad body with a thickness of 3-15 mm, the pad body comprising two or more soft elastic foam layers; and at least one reinforcing layer is provided between adjacent soft elastic foam layers.

[0006] Preferably, the soft elastic foam layer is a PU foam layer or an acrylic foam layer, and the thickness of the soft elastic foam layer is 0.2 to 5 mm.

[0007] Preferably, the reinforcing layer is one of PU resin film, TPU film, PE film, CPU film, acrylic resin film, PI film and TPE film, and the reinforcing layer is a liquid raw material coated and cured film or a finished elastic lamination film, and the thickness of the reinforcing layer is 0.005 to 0.3 mm.

[0008] Preferably, the upper and / or lower surfaces of the pad are provided with a surface reinforcement film or a coating film.

[0009] A processing technology for a high-toughness, fracture-resistant foamed composite pad, the processing technology comprising the following steps:

[0010] The process involves: first foaming to form the first soft elastic foam layer; online film application or resin coating and curing to form a film on the soft elastic foam layer; second foaming directly on the reinforcing film; achieving glue-free integral bonding between the reinforcing layer and the soft elastic foam layer through material self-curing; and obtaining the composite pad of the required thickness according to processing requirements.

[0011] By adopting the aforementioned technical solution, the beneficial effects of the present invention are:

[0012] 1. This high-toughness, fracture-resistant foamed composite mat and its processing technology solve the core problems of insufficient toughness and easy breakage when bending existing PU foamed yoga mats, crawling mats and other similar products: through the structure of the PU foam layer and the reinforcing layer, the excellent toughness and tensile strength of the reinforcing layer are used to disperse the stress generated when the yoga mat is bent, and avoid the PU foam layer from cracking and breaking due to stress concentration, thus solving the problems mentioned in the background technology.

[0013] 2. The high-toughness, fracture-resistant foamed composite mat and its processing technology: The core material of this invention is still the PU foam layer. No toughening agents that affect the performance of PU materials are added. Moreover, foaming is carried out directly on the reinforcing layer without the need for additional adhesives. Therefore, it can fully retain the advantages of PU foam material such as high elasticity, softness, environmental protection and non-toxicity, and good skin-friendliness, ensuring the user experience of the yoga mat. At the same time, it meets national environmental protection standards and has no odor or release of harmful gases.

[0014] 3. The high-toughness, fracture-resistant foamed composite pad and its processing technology: The processing technology of this invention is based on existing PU foaming technology and hot-pressing bonding technology. It does not require the addition of complex production equipment. Only simple adjustments are needed to existing equipment to achieve large-scale industrial production. Moreover, the process parameters are clear and controllable, the product qualification rate is high, the production cost is low, and it is easy to promote and apply. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the structure of the present invention.

[0016] In the diagram: 1. Foaming layer; 2. Reinforcing layer. Detailed Implementation

[0017] Please see Figure 1The present invention provides a technical solution: a high-toughness fracture-resistant foamed composite pad, comprising a pad body with a thickness of 3 to 15 mm, wherein the pad body comprises two or more soft elastic foam layers 1; and at least one reinforcing layer 2 is provided between adjacent soft elastic foam layers 1.

[0018] The soft elastic foam layer 1 is a PU foam layer or an acrylic foam layer, and the thickness of the soft elastic foam layer 1 is 0.2 to 5 mm.

[0019] The reinforcing layer 2 is one of PU resin film, TPU film, PE film, CPU film, acrylic resin film, PI film and TPE film. The reinforcing layer 2 is a liquid raw material coated and cured film or a finished elastic laminated film. The thickness of the reinforcing layer 2 is 0.005 to 0.3 mm.

[0020] It should be noted that the materials for the reinforcing layer 2 are not limited to the above-mentioned materials. Based on the product's requirement for toughness, it can also be extended to high-toughness elastic polymers such as EVA film and soft PVC film.

[0021] The preferred PE reinforced film has a tensile strength of ≥25MPa in the longitudinal direction and ≥20MPa in the transverse direction, and an elongation at break of ≥550% in the longitudinal direction and ≥650% in the transverse direction. It has excellent toughness and tensile strength, which can effectively disperse the stress generated when the yoga mat is bent and prevent the PU foam layer from breaking. At the same time, it has good adhesion and can be tightly bonded to the PU foam layer without affecting the overall softness of the yoga mat.

[0022] The upper and / or lower surfaces of the pad are provided with a surface-reinforcing film or a coating film, preferably a PU film.

[0023] Example

[0024] This processing technology is based on the structural design of the composite pad described above. The total thickness of the finished product is 4mm, and it adopts a three-stage foaming and two-layer reinforcing structure.

[0025] 1. The first foaming process forms a 1mm thick PU foam layer;

[0026] 2. Apply PU resin or acrylic resin online and cure to form a 0.02mm thick reinforcing layer;

[0027] 3. Secondary foaming is performed directly on the reinforcing layer to form a 2mm thick PU foam layer;

[0028] 4. Apply a second 0.02mm thick reinforcing layer online;

[0029] 5. The third foaming process forms a 1mm thick PU foam layer.

[0030] The overall structure consists of: a 1mm foam layer + a reinforcing layer + a 2mm foam layer + a reinforcing layer + a 1mm foam layer, with a total thickness of approximately 4mm. All layers are integrally bonded without glue, making it resistant to breakage even after repeated bending, and its tear resistance is significantly superior to that of one-piece molded thick foam pads.

[0031] It should be noted that the above is only one of the many embodiments of this technical solution. Based on this solution, production can be carried out directly according to product requirements. Theoretically, the toughness of the product can increase with the number of foam layers. The more times foaming, the stronger the toughness of the final product. Furthermore, by adjusting the density, hardness, and resilience of each layer of foam according to product requirements, different performance ranges can be formed on the composite pad product to meet the personalized customization of customers.

[0032] Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the invention. Therefore, the invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A high-toughness, fracture-resistant foamed composite pad, comprising a pad body, characterized in that: The thickness of the pad is 3 to 15 mm, and the pad includes two or more soft elastic foam layers; at least one reinforcing layer is provided between adjacent soft elastic foam layers.

2. The high-toughness, fracture-resistant foamed composite pad according to claim 1, characterized in that: The soft elastic foam layer is a PU foam layer or an acrylic foam layer, and the thickness of the soft elastic foam layer is 0.2 to 5 mm.

3. The high-toughness, fracture-resistant foamed composite pad according to claim 2, characterized in that: The reinforcing layer is one of PU resin film, TPU film, CPU film, PE film, acrylic resin film, PI film and TPE film. The reinforcing layer is a liquid raw material coated and cured film or a finished elastic laminated film. The thickness of the reinforcing layer is 0.005 to 0.3 mm.

4. The high-toughness, fracture-resistant foamed composite pad according to claim 1, characterized in that: The upper and / or lower surfaces of the pad are provided with a surface reinforcement film or a coating film.

5. The processing technology of a high-toughness, fracture-resistant foamed composite pad according to any one of claims 1-4, characterized in that: The processing technology includes the following steps: The process involves: first foaming to form the first soft elastic foam layer; online film application or resin coating and curing to form a film on the soft elastic foam layer; second foaming directly on the reinforcing film; achieving glue-free integral bonding between the reinforcing layer and the soft elastic foam layer through material self-curing; and obtaining the composite pad of the required thickness according to processing requirements.

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