Adhesive-free bonding preparation method and forming method for elastic pad

Abstract

The present application discloses an adhesive-free bonding preparation method for an elastic pad, comprising: first providing a base material, the base material comprising a sheet formed by mixing natural rubber with a foaming agent and a related additive and then pressing the mixture; then providing a disruptive material on the surface of the base material, the disruptive material comprising a foaming agent and a foaming aid; instantly heating the disruptive material, causing the disruptive material to undergo a chemical reaction to damage the surface of the base material; applying a face material to the surface of the base material; heating and bonding the base material and the face material to partially cure the base material, and applying a strengthening means, comprising applying external force to the face material, causing the disruptive material at the contact surface between the face material and the base material to be strengthened by the external force, thereby facilitating the connection between the face material and the base material; applying pressure to the outer sides of the face material and the base material to promote the bonding between the face material and the base material; and finally, heating the face material and the base material to fully cure the base material, thereby obtaining an elastic pad.

Description

A method for preparing and forming an elastic pad without adhesive bonding Technical Field

[0001] This application relates to the field of materials technology, and in particular to a method for preparing an elastic pad using adhesive-free bonding. Background Technology

[0002] Typically, elastic mats are formed by bonding a rubber sheet to a surface material with different physical properties (such as fiber fabric). The technique involves applying an adhesive or bonding agent to the surface of the rubber sheet before it has fully cured and set, then placing the surface material on top and sending both sheets into a vulcanizing foaming chamber for curing. However, this method of bonding the surface material to the rubber sheet using adhesives or bonding agents leads to environmental problems such as air and water pollution during the production process.

[0003] [Amended according to Rule 26, 30.09.2024] To this end, the inventor developed Taiwan Patent Application No. 200607634, "Preparation Method of Continuous Rubber Embossed Foam," many years ago. It mainly utilizes the gas pressure generated by the chemical change of the foaming agent added to the rubber sheet material to bond the surface material. No adhesive or bonding agent is needed. The inventor calls it glueless bonding technology. This process is more environmentally friendly and is currently widely used in the industry.

[0004] [Amended according to Article 26, September 2024] Secondly, in order to solve the problems of slow water absorption speed of woven fabric absorbent mats and poor tactile feel, easy breakage and easy slippage of rigid diatomaceous earth absorbent mats (requiring the use of anti-slip mats) in the prior art, the inventors have successively developed elastic absorbent mats in recent years, which are patented in Taiwan No. I693909, No. I729845 and No. M582806 and No. M601062. These mats not only absorb water faster, but also have a soft feel and do not slip on the ground. Therefore, they can indeed solve the shortcomings of the aforementioned different types of absorbent mats in the prior art. These elastic absorbent mats are already sold in most stores and mass-market channels, and the user feedback is very good. These elastic absorbent mats are also elastic mats, and the bonding method between the surface material and the rubber sheet also utilizes the aforementioned glue-free bonding technology of elastic mats. However, the adhesion between the face material and the rubber sheet needs to be further improved.

[0005] Summary of the Invention

[0006] To address the aforementioned technical problems, this application discloses a method for preparing an elastic pad using adhesive-free bonding.

[0007] To achieve the above-mentioned objectives, the adhesive-free bonding method for preparing the elastic pad of this application includes at least the following:

[0008] Providing a substrate: A substrate is provided, the substrate comprising a sheet formed by mixing and pressing natural rubber with related additives; Setting a destructive material: A destructive material is set on the surface of the substrate, the destructive material comprising a mixture of foaming agent and foaming aid; Instant heating: The destructive material is instantaneously heated, causing a chemical reaction that destructs the surface of the substrate; Applying a face material: A face material is applied to the surface of the substrate where the destructive material is located; Heating and strengthening: The substrate and face material are heated and bonded together, partially curing the substrate, while simultaneously applying a strengthening method, the strengthening method including applying external force to the face material, so that the destructive material at the contact surface between the face material and the substrate is strengthened by the external force, making the face material and the substrate easier to bond; Applying pressure: Pressure is applied to the outer side of the face material and the substrate to promote the bonding of the face material and the substrate; Curing: The face material and the substrate are heated, so that the substrate is fully cured, thereby obtaining an elastic pad.

[0009] Preferably, in the step of providing the substrate, the substrate is placed on a continuously moving support member, and after the maturation step, the elastic pad is separated from the support member, which includes an embossing mold that can create texture on one side of the substrate.

[0010] Preferably, the defoaming material further includes a defoamer, an antifoamer, and / or an elastic material.

[0011] Preferably, the substrate and the destructive material further include water-absorbing material powder.

[0012] Preferably, in the instantaneous heating step, the instantaneous heating temperature is at least the temperature at which the foaming agent can produce a chemical reaction and generate gas.

[0013] Preferably, in the step of applying the surface material, the surface material is a fiber sheet.

[0014] Preferably, in the heating and strengthening step, the strengthening means can be any one or a combination of at least two physical means such as wind power, radio waves, lasers or magnetic waves.

[0015] Preferably, the strengthening method is wind power, which allows part of the surface of the substrate and part of the damaging material to extend into the face material.

[0016] Preferably, the strengthening method is negative pressure wind.

[0017] Preferably, in the heating and strengthening step, the step of partially maturing the substrate to fully maturing involves heating at least once until the substrate is fully maturated.

[0018] Compared with the prior art, the beneficial effects of this application are as follows:

[0019] The adhesive-free bonding method for the elastic pad provided in this application utilizes the destructive effect of the destructive material on the surface of the substrate when it undergoes a chemical change due to instantaneous heating, combined with the reinforcement method applied to the surface material, to bond the substrate and surface material with different properties without the need for adhesives, making it more environmentally friendly.

[0020] The support member, which can be separated from the substrate, can also form a predetermined texture on one side of the substrate.

[0021] Compared to the glueless bonding method of elastic pads in the prior art, this application only uses the gas pressure generated by the foaming agent in the substrate to bond the substrate to the surface material. This can make the adhesion between the substrate and the surface material better, and the adhesion between the surface material and the rubber sheet better, making the surface material less likely to separate from the substrate and more practical. Attached Figure Description

[0022] To more clearly illustrate the adhesive-free bonding preparation method of the elastic pad described in this application, the accompanying drawings required for the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0023] Figure 1 is a flowchart of the adhesive-free bonding preparation process of the elastic pad of this application.

[0024] Figure 2 is a schematic diagram of the structure of the elastic pad in Embodiment 1 of this application.

[0025] Figure 3 is a schematic diagram of the adhesive-free bonding equipment for the elastic pad of this application.

[0026] Figure 4 is a schematic diagram of the structure of the elastic pad in Embodiment 2 of this application.

[0027] Among them: 1-base material, 2-damaging material, 3-surface material, 4-supporting component, 10-elastic absorbent floor mat. Detailed Implementation

[0028] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of them. All other embodiments obtained by those skilled in the art based on the embodiments of this application without creative effort are within the scope of protection of this application.

[0029] As used herein, "an embodiment" or "an embodiment" refers to a specific feature, structure, or characteristic that may be included in at least one implementation of this application. The invention will be more readily understood by referring to the following detailed description of preferred embodiments and included examples. Unless otherwise specified, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. In case of conflict, the definitions in this specification shall prevail.

[0030] For the terms defined below, unless a different definition is given elsewhere in the claims or this specification, these definitions shall apply. All numerical values, whether explicitly indicated or not, are defined herein as being modified by the term "about." The term "about" generally refers to a range of numerical values ​​that a person skilled in the art would consider equivalent to the stated values ​​to produce substantially the same properties, functions, results, etc. A range of numerical values ​​indicated by a low value and a high value is defined as including all numerical values ​​included within that range and all subranges included within that range.

[0031] Although the numerical ranges and parameters illustrating the broad scope of the invention are approximate, the values ​​listed in the specific examples are reported as precisely as possible. However, any numerical value inherently contains some error that is necessarily caused by the standard deviation found in their respective test measurements.

[0032] When a numerical range is disclosed herein, the range is considered continuous and includes the minimum and maximum values ​​of the range, as well as every value between such minimum and maximum. Further, when the range refers to an integer, it includes every integer between the minimum and maximum values ​​of the range. Additionally, when multiple ranges are provided to describe a feature or characteristic, the ranges may be combined. In other words, unless otherwise specified, all ranges disclosed herein should be understood to include any and all subranges to which they are included. For example, a specified range from “1 to 10” should be considered to include any and all subranges between the minimum value 1 and the maximum value 10. Exemplary subranges of the range 1 to 10 include, but are not limited to, 1 to 6.1, 3.5 to 7.8, 5.5 to 10, etc.

[0033] It should be noted that the terms "first," "second," etc., in the specification, claims, and accompanying drawings of this application are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate so that the embodiments of this application described herein can be implemented in orders other than those illustrated or described herein. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover non-exclusive inclusion.

[0034] The following examples illustrate a method for preparing an elastic pad without adhesive bonding provided in this application.

[0035] Example 1

[0036] Referring to Figures 1-2, the first step is to provide substrate 110: Substrate 1 is provided, which is a sheet formed by adding foaming agents (such as azodicarbonamide ADC / AC, nitrosyl foaming agents, oxobenzenesulfonyl hydrazine, benzenesulfonyl hydrazine, etc., in this embodiment azodicarbonamide, but the use of other foaming agents is not limited) and foaming aids (such as accelerators, inhibitors, stabilizers, and catalysts) to natural rubber refined from rubber tree latex, mixed with absorbent material powder (which is only added when the elastic mat prepared in this invention is used as an absorbent floor mat), and then pressing it out. The foaming agents, foaming aids, and other additives are existing additives for controlling the foaming and vulcanization molding of natural rubber, and their detailed composition and foaming principle will not be described here.

[0037] The second step is to set the destructive material 120: a destructive material 2 is set on the surface of the substrate 1. The destructive material can be set on the surface of the substrate by coating or spraying, but other methods are not limited. The destructive material includes a foaming agent, a foaming aid, a defoamer / defoamer and / or absorbent material powder (only needed when the elastic pad prepared by this invention is used as an absorbent floor mat), and an elastic material (liquid or solid). The foaming agent and foaming aid are the same as those added to the substrate 1, but are not limited. The defoamer / defoamer is a rubber defoamer in the prior art, used to break the bubbles generated on the surface of the substrate 1 by the action of the foaming agent, and to adjust the foaming effect of the foaming agent. The absorbent material powder includes mineral powders such as diatomaceous earth, clay, clay, and sand, and / or plant powders such as cotton and agar, and / or chemical powders such as sludge, slag, superabsorbent resin, nylon, and polyacrylate, but is not limited to diatomaceous earth in this embodiment. Its elastic material can be a thermoplastic elastic material in the prior art, such as PU (TPU), TPR, and natural rubber, but is not limited thereto. The addition ratios of each foaming agent, foaming aid, defoamer, absorbent material powder, and elastic material are not limited; they only need to be able to damage the surface of the substrate 1. In addition, the absorbent material powder is used to absorb moisture, and the elastic material is used for bonding.

[0038] The third step is instantaneous heating 130: Instantly heating the aforementioned destructive material 2 causes a chemical reaction in the destructive material 2, thereby damaging the surface of the substrate 1. The instantaneous heating temperature is at least the temperature at which the foaming agent and defoaming agent can produce a chemical reaction. For example, the decomposition temperature of azodicarbonamide foaming agent is approximately 195°C to 120°C, so the instantaneous heating temperature is above 195°C. During instantaneous heating, the surface of the substrate 1 will also soften due to heat, making it easily damaged by the foaming gas pressure and defoaming interaction of the foaming agent and defoaming agent in the destructive material 2. In addition, when the elastic material added to the destructive material 2 is solid, the instantaneous heating temperature can also soften the elastic material, causing the softened elastic material to be damaged and separated by the interaction of the foaming agent and defoaming agent.

[0039] The fourth step is to apply the face material 140: When the damaging material 2 undergoes a chemical reaction and damages the surface of the substrate 1, the face material 3 is laid on the surface of the substrate 1. The substrate 1 and the face material 3 then gradually bond together due to the chemical reaction initiated by the damaging material 2. The face material 3 is a fibrous sheet, such as fabric.

[0040] The fifth step is heating and strengthening 150: heating and bonding the substrate 1 and the face material 3 while simultaneously applying a strengthening method. This strengthening method involves applying external force to the face material 3, making it easier for the face material 3 and the substrate 1 to connect. The aforementioned heating method involves feeding the substrate 1 and the face material 3 into an oven. The face material 3 and the substrate 1 can naturally bond through the interaction of the foaming gas pressure of the foaming agent in the defoaming material 2 and the defoaming action of the defoaming agent. The heating temperature is sufficient to mature the substrate 1 to about a semi-mature state. This strengthening method is carried out inside the oven, but other heating facilities outside the oven are not limited. This strengthening method can be any one or a combination of at least two physical methods such as wind power, radio waves, lasers, or magnetic waves. This strengthening method can reach the defoaming material 2 through the material gaps of the face material 3, improving the connection between the defoaming material 2 and the face material 3. Moreover, the softened and separated elastic material in the defoaming material 2 can further assist in connecting the face material 3 and the substrate 1.

[0041] The sixth step is applying pressure 160: After the face material 3 and the substrate 1 have been strengthened, pressure is then applied to the outer side of the face material 3 and the substrate 1 to promote adhesion between the face material 3 and the substrate 1. The pressure can be applied by feeding the face material 3 and the substrate 1 into a rolling mill for pressure, but is not limited to using a rolling mill.

[0042] The final step of the present invention is curing 170, which includes heating the face material 3 and the substrate 1 in an oven until the substrate 1 is fully cured, thereby obtaining an elastic absorbent mat 10. The face material 3 and the substrate 1 can be cured by heating in one oven or by heating in multiple ovens to gradually cure them.

[0043] Therefore, the adhesive-free bonding method 100 for the elastic mat of this application utilizes the instantaneous heating after applying a destructive material 2 to the surface of the substrate 1, causing the destructive material 2 to undergo a chemical reaction and destroy the surface of the substrate 1. Then, a face material 3 is attached to the substrate 1, allowing the substrate 1 and face material 3 to naturally bond together due to the gas pressure generated by the foaming agent in the destructive material 2 and the interaction of the defoaming agent. Furthermore, the substrate 1 and face material 3 are heated and reinforced simultaneously to enhance the bonding strength between them. Finally, without the need for adhesive, the substrate 1 and face material 3 can be bonded together to form the elastic mat 10. Moreover, when absorbent material powder is added to the materials of the substrate 1 and the destructive material 2, the elastic mat 10 can be used as an absorbent floor mat.

[0044] Example 2

[0045] Referring to Figure 3, the adhesive-free bonding method 200 for the elastic pad of this application has largely the same steps as the adhesive-free bonding method 100, except that: the substrate 1 is bonded to a continuously moving support member 4 (e.g., placed on a conveyor belt, not shown in the figure). The support member 4 is a release fabric that can create texture on one side of the substrate 1, but other materials are not limited. The support member 4 is separated from the elastic pad 10 after the curing step 170. Next, in the heating and strengthening step 150, the strengthening means can be negative pressure airflow, so that part of the surface of the substrate 1 and part of the damaged material 2 can be attracted by negative pressure and extended into the face material 3, as shown in Figure 4. In addition, in the curing step 170, secondary heating can be used to sequentially cure 70%, 85% until the final curing is completed. In this way, after the support member 4 is separated from the elastic pad 10, the surface of the substrate 1 can form a predetermined texture under the action of the support member 4.

[0046] Alternatively, this application can also prepare an elastic pad with multiple layers of fiber cloth (i.e., the surface material 3). Simply by placing a disruptive material 2 containing elastic material between each layer of fiber cloth, the disruptive material 2 can connect the layers. Specifically, after repeating the steps of placing the disruptive material 120, instant heating 130, attaching the surface material 140, and heating and strengthening 150 several times, the steps of applying pressure 160 and curing 170 are then performed. Furthermore, various types of recycled materials can be added to the substrate 1 of this invention, enabling the invention to utilize recycled waste as materials.

[0047] As can be seen from the above, the adhesive-free bonding method for the elastic pad provided in this application only utilizes the destructive effect of the destructive material undergoing a chemical change due to instantaneous heating on the surface of the substrate, combined with the reinforcement method applied to the surface material, to bond the substrate and surface material with different properties. This eliminates the need for adhesives and is more environmentally friendly. Furthermore, a predetermined texture can be formed on one side of the substrate using a support member that can be separated from the substrate. Compared to the adhesive-free bonding methods for elastic pads in the prior art, this application only utilizes the gas pressure generated by the foaming agent in the substrate to bond the substrate to the surface material, resulting in better adhesion between the substrate and the surface material. The surface material is less likely to separate from the substrate, making it more practical.

[0048] Of course, the surface material in the manufacturing method of the present invention is not limited to cloth, but can also be a plastic film or other materials, so as to improve the diversity of elastic pad products and increase the uses of the products.

[0049] The above-disclosed embodiments are merely preferred embodiments of this application. It should be noted that any modifications made by those skilled in the art to the specific implementation methods of this application do not depart from the scope of the claims. Accordingly, the scope of the claims of this application is not limited to the aforementioned specific embodiments.

Claims

1. A method for preparing an elastic pad using adhesive-free bonding, characterized in that, The preparation method includes at least the following steps: Provide a substrate: Provide a substrate comprising a sheet formed by mixing natural rubber with related additives and pressing it into a sheet; Setting a destructive material: A destructive material is provided on the surface of the substrate, the destructive material comprising a mixture of a foaming agent and a foaming aid; Instantaneous heating: Instantly heating the damaging material to cause a chemical reaction that damages the substrate surface; Applying a surface material: Applying a surface material to the surface of the substrate where the destructive material is located; Heating and strengthening: heating and bonding the substrate and the face material to cure the substrate portion, while simultaneously applying a strengthening method, the strengthening method including applying external force to the face material, so that the destructive material at the contact surface between the face material and the substrate is strengthened by the external force, thereby making the face material and the substrate easier to connect. Applying pressure: Applying pressure to the outer side of the face material and the substrate to promote adhesion between the face material and the substrate; Curing: Heating the face material and the substrate to fully cure the substrate, thereby obtaining an elastic pad.

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

3. The adhesive-free bonding preparation method according to claim 1 or 2, characterized in that, The destructive material also includes defoamers, antifoamers, and / or elastic materials.

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

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

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

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

8. The adhesive-free bonding preparation method according to claim 7, characterized in that, The strengthening method is wind power, which allows part of the surface of the substrate and part of the damaged material to extend into the face material.

9. The adhesive-free bonding preparation method according to claim 8, characterized in that, The aforementioned enhancement method is negative pressure wind.

10. The adhesive-free bonding preparation method according to claim 1 or 2, characterized in that, In the heating and strengthening step, the substrate is partially matured to fully matured, and at least once is heated until the substrate is fully matured.

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