CN110733156A - 一种聚氨酯垫层的加工工艺及人造草坪垫层 - Google Patents
一种聚氨酯垫层的加工工艺及人造草坪垫层 Download PDFInfo
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Abstract
本发明公开了一种聚氨酯垫层的加工工艺以及人造草坪垫层。其中,聚氨酯垫层的加工工艺主要包括粉碎步骤、筛选步骤、混合步骤、发泡步骤和切割步骤。该工艺采用回收的聚氨酯边角料作为原料,结合特定的制备加工工艺,制备出减震性能较佳、回弹性好、具有良好的渗水性能和保水性能的聚氨酯垫层,以使得聚氨酯垫层的性能满足运动场的要求;且生产成本大大地降低,从而以使得聚氨酯垫层能够被广泛地运用于运动场合中。将该工艺制备出来的聚氨酯垫层应用于人造草坪垫层中,可以使得该草坪垫层既能满足运动场合的需要,又能大大地降低应用的成本。
Description
技术领域
本发明涉及人造草坪技术领域,尤其涉及一种聚氨酯垫层的加工工艺及人造草坪垫层。
背景技术
为了模仿天然草坪,现有的运动场一般会铺设一层薄薄的人造草坪,再在人造草坪下方设置有一层人造草坪垫层或者充砂,以保证运动场的性能符合运动者的需求。
目前,市场上人造草坪垫层的材质多为聚乙烯合成物为主,此垫层在使用过程中普遍存在回弹性能不佳、易发生因热胀冷缩而导致的垫层变形、密实度低、使用寿命不长等缺点。其应用在运动场合下,特别是足球运动场,因上述缺点而导致运动场的减震和缓冲性能下降,使用寿命缩短等问题。由于聚氨酯弹性好,具有优良的复原性,所以,现有技术中,有的厂家将聚氨酯材料运用于人造草坪中;但是,由于人造草坪是薄薄的一层,变形量有限,所以对于运动场的性能提升所起的作用也并不是很大。也有的厂家尝试将聚氨酯材料运用于人造草坪垫层中。但是,由于聚氨酯颗粒的价格昂贵,所以,加工出来的垫层成本高。如此昂贵的垫层运用于运动场合上,对于买家而言有点大材小用,所以,从经济角度出发,买家更倾向于使用聚乙烯材质垫层,因此,厂家一般不会考虑采用聚氨酯材料来制作垫层,运用于人造草坪垫层中。
发明内容
为了克服现有技术的不足,本发明的目的在于:提供一种聚氨酯垫层的加工工艺,该加工工艺制备出来的聚氨酯垫层减震性能较佳、回弹性好、具有良好的渗水性能和保水性能;且生产成本大大降低,从而使得聚氨酯垫层能够被广泛地运用于运动场合中。
本发明的目的之一采用如下技术方案实现:
一种聚氨酯垫层的加工工艺,包括以下步骤:
粉碎步骤:将回收的聚氨酯边角料倒入粉碎机中,粉碎成细小的聚氨酯颗粒。与纯正的聚氨酯颗粒相比,本发明采用回收的聚氨酯边角料作为原料,原料价格低,从本源上大大降低聚氨酯垫层的生产成本。
筛选步骤:对所述粉碎步骤中细小的聚氨酯颗粒进行筛选,筛选出直径为 2-5mm的聚氨酯颗粒。
混合步骤:将筛选出来的聚氨酯颗粒与聚氨酯粘合剂按10:1的比例加入搅拌机中搅拌均匀,倒入模具中。
发泡步骤:用运输带将模具运输至发泡箱中,将100-120℃蒸汽通入发泡箱中使混合物发泡定型,得到聚氨酯垫层半成品;其中,蒸汽通入时间为30-45min。发泡使混合物产生微孔结构,定型形成垫层。
切割步骤:将聚氨酯垫层半成品置于自然状态下放置24-30小时,待垫层稳定后,对垫层进行切割修边,从而得到聚氨酯垫层。
上述制备工艺中,采用回收的聚氨酯边角料作为聚氨酯垫层的原料,对废弃了的聚氨酯边角料进行回收再利用,大大降低生产成本,且绿色环保。但是,由于采用的原料聚氨酯边角料是已经进行过一次成型了的,所以其纯度与纯正的聚氨酯颗粒相比较低,即其弹性、复原性与纯正的聚氨酯颗粒相比,会稍微有点差。为了弥补原材料性能略差这一缺陷,本发明采用特定的制备工艺进行制备,从而保证制备出来的聚氨酯垫层在性能上符合运动场合的要求。
本发明所制备的聚氨酯垫层的弹力一部分来源于聚氨酯材料本身,另一部分来源于垫层中形成的微孔结构。所以,本发明中的粘合剂除了起到连接聚氨酯颗粒的作用外,与筛选出来的聚氨酯颗粒形成混合物,有利于蒸汽在混合物中,形成微孔结构,从而保证用回收边角料制备而成的垫层的弹性、复原性较好,符合运动场的要求。其次,本发明优选筛选出来的聚氨酯颗粒直径为2-5mm。如果直径太小,聚氨酯颗粒的纯度就会很低,即所含聚氨酯材料较少,从而影响到后续制备出来的垫层的性能。如果直径太大,制备而成的垫层的密实度过低,垫层的性能也会较差。此外,如果直径过大还可能会使得后期发泡过程中不能很好地形成均匀、统一的微孔结构,从而影响垫层的性能。然后,将筛选出来的聚氨酯颗粒与粘合剂按10:1的比例混合,有利于后期发泡过程中形成均匀、统一的微孔结构,也保证了聚氨酯颗粒之间的能够很好地连接在一起,即保证垫层的拉伸强度。如果粘合剂过少,则形成的微孔量少,且不均匀,从而导致垫层的性能较差;还可能导致聚氨酯颗粒不能很好地连接于一起,从而降低垫层的拉伸强度。如果粘合剂过多,即单位体积内含有的聚氨酯颗粒较少,导致垫层的性能主要依靠微孔结构,因此垫层的弹性、复原性会降低。与传统的连续发泡成型工艺相比,由于本发明加入的粘合剂较多,且需要形成微孔结构,而连续发泡成型无法让混合物很好地形成均匀、统一的微孔结构,所以,本发明需要采用片状批次发泡成型。发泡的温度设置为100-120℃,30-45min可以很好地保证混合物能形成均匀、统一的微孔结构,从而保证垫层的性能,使其变形更加稳定。该条件下形成的微孔结构还能保证垫层良好的渗水性能,以及垫层良好的保水性能。因为形成的微孔可以吸收一定的水分。当该垫层运用于草坪时,当草坪温度过高时,蒸发吸收的水分,带走草坪的温度,从而缓解草坪的温度;但是又不会过分地吸收水分,以防下雨天草坪积水。最后,切割步骤中,半成品垫层需要置于自然状态下稳定后,在进行切割修边,否则垫层尚未稳定便进行切割修边,垫层容易变形。
上述加工工艺制备出来的聚氨酯垫层的密度为150kg/m3,微孔直径约为 0.4-0.5mm,微孔与微孔之间的间距为0.2-0.3mm。
作为进一步实施例,所述发泡步骤中,通入的蒸汽的温度为110℃。110℃能够发泡过程更加稳定地进行,从而更好地形成微孔结构。
本发明的目的之二在于:提供一种人造草坪垫层,该减震性能较佳、密实度高、具有良好的渗水性能和保水性能。
本发明的目的之二采用如下技术方案实现:
一种人造草坪垫层,包括上述任一项实施例所制备的聚氨酯垫层。采用本发明工艺制备的聚氨酯垫层制作而成的人造草坪垫层,既能满足运动场合的需要,又能大大地降低应用的成本。
作为进一步实施例,所述聚氨酯垫层为20mm。与现有技术中,薄薄的一层聚氨酯人造草坪(约3-5mm)相比,本实施例中的聚氨酯人造草坪垫层为20mm,其变形量显然优于聚氨酯人造草坪。
作为进一步实施例,还包括第一无纺布层,所述第一无纺布层粘合于所述聚氨酯垫层上表面。本实施例中,第一无纺布相当于一层保护膜,保护着其下方的聚氨酯垫层,从而增强整个草坪垫层的抗撕裂能力。其次,聚氨酯垫层上方覆一层无纺布,可以使得人造草坪垫层表面更加美观大方。
作为进一步实施例,所述聚氨酯垫层为10mm-20mm。根据场地的弹性需求,客户可以选择不同的厚度的聚氨酯垫层。当聚氨酯垫层厚度较小时,人造草坪垫层的弹性较低,减震性能较差;当聚氨酯垫层厚度较大时,人造草坪垫层的弹性较高,减震性能较好。本发明所制备的聚氨酯垫层厚度选为10-20mm,既能保证人造草坪垫层的回弹性能,也能保证人造草坪垫层的减震性能。
作为进一步实施例,所述人造草坪垫层的加工流程具体如下:将无毒无害无味的水性胶涂覆在聚氨酯垫层的一面上,采用贴合机将第一无纺布层压紧于涂覆有聚氨酯垫层的一面上,使第一无纺布层与聚氨酯垫层贴合于一起。由于无纺布层的材质与聚氨酯垫层的材质不一样,本实施例将贴合温度设置为 180-200℃,水性胶使用量设置为每平方60-70克,从而使得该条件下的水性胶上表面既能很好地与无纺布表面贴合,下表面又能很好地与聚氨酯垫层表面贴合,进而紧密地将无纺布层和聚氨酯垫层粘合于一起,增强人造草坪垫层的抗撕裂能力。
作为进一步实施例,还包括第二无纺布层,所述第二无纺布层粘合于所述聚氨酯垫层下表面。第二无纺布层与第一无纺布层配合,实现聚氨酯垫层的全方位保护,进一步增强整个草坪垫层的抗撕裂能力。
作为进一步实施例,所述聚氨酯垫层为10mm-20mm。
相比现有技术,本发明的有益效果在于:
本发明提供一种聚氨酯垫层的加工工艺,该工艺采用回收的聚氨酯边角料作为原料,结合特定的制备加工工艺,制备出减震性能较佳、回弹性好、具有良好的渗水性能和保水性能的聚氨酯垫层,以满足运动场的性能要求;且生产成本大大地降低,从而使得聚氨酯垫层能够被广泛地运用于运动场合中。将该工艺制备出来的聚氨酯垫层应用于人造草坪垫层中,可以使得该草坪垫层既能满足运动场合的需要,又能大大地降低应用的成本。
附图说明
图1为本发明提供的人造草坪垫层一较优实施例的结构示意图。
图中:1、第一无纺布层;2、聚氨酯垫层;3、第二无纺布层。
具体实施方式
下面,结合附图以及具体实施方式,对本发明做进一步描述,需要说明的是,在不相冲突的前提下,以下描述的各实施例之间或各技术特征之间可以任意组合形成新的实施例。
本发明的一种聚氨酯垫层的加工工艺,主要包括以下步骤:
粉碎步骤:将回收的聚氨酯边角料倒入粉碎机中,粉碎成细小的聚氨酯颗粒。
筛选步骤:对所述粉碎步骤中细小的聚氨酯颗粒进行筛选,筛选出直径为 2-5mm的聚氨酯颗粒。
混合步骤:将筛选出来的聚氨酯颗粒与聚氨酯粘合剂按10:1的比例加入搅拌机中搅拌均匀,倒入模具中。发泡过程采用粘合剂将聚氨酯颗粒连接于一起,以便后期成型为垫层。
发泡步骤:用运输带将模具运输至发泡箱中,将100-120℃蒸汽通入发泡箱中使混合物发泡定型,得到聚氨酯垫层半成品;其中,蒸汽通入时间为30-45min。发泡使混合物产生微孔结构,定型形成垫层。进一步地,蒸汽的温度优选为 110℃。
切割步骤:将聚氨酯垫层半成品置于自然状态下放置24-30小时,待垫层稳定后,对垫层进行切割修边,从而得到聚氨酯垫层。
上述加工工艺制备出来的聚氨酯垫层的密度为150kg/m3、微孔直径为0.4-0.5mm和微孔与微孔之间的间距为0.2-0.3mm。该加工工艺制备出来的聚氨酯垫层减震性能较佳、回弹性好、具有良好的渗水性能和保水性能,以满足运动场的性能要求;且生产成本大大降低,以使得聚氨酯垫层能够被广泛地运用于运动场合中。
采用本发明加工制备出来的聚氨酯垫层的相关性能如表1所示:
表1
测试项目 | 测试方法 | 测试结果 |
厚度 | EN 1969 | 10.5mm |
冲击吸收 | FIFA Test Method 04a | 41.8% |
垂直变形 | FIFA Test Method 05a | 6.2mm |
拉力强度 | EN 12230 | 0.18Mpa |
单位面积重量 | EN 430 | 1561g/m<sup>2</sup> |
渗水性能 | EN 12616 | >2000mm/h |
冲击吸收是指垫层受到冲击时,对势能的吸收性能,即垫层的减震性能。垂直变形是指重物以规定的高度落下时,垫层垂直方向的变形,也侧面反映了垫层的回弹性能。拉力强度是指在拉伸试验中,试样直至断裂为止所受的最大拉伸应力。如表1所示,本发明制备的聚氨酯垫层的冲击吸收、垂直变形、拉力强度以及渗水性能均较好,即侧面体现了垫层的减震性能较佳、回弹性能好、具有良好的渗水性能和保水性能。
将上述工艺制备出来的聚氨酯垫层运用于人造草坪垫层中,既能满足运动场合的需要,又能大大地降低应用的成本。
实施例1:
一种人造草坪垫层,包括聚氨酯垫层。本实施例中,该聚氨酯垫层厚度优选为20mm。
实施例2:
一种人造草坪垫层,包括聚氨酯垫层和第一无纺布层。其中,第一无纺布粘合于聚氨酯垫层上表面。与实施例1相比,本实施例中,第一无纺布相当于一层保护膜,保护着其下方的聚氨酯垫层,从而增强了整个草坪垫层的抗撕裂能力;其次,也使得人造草坪垫层表面更加美观大方。本实施例中,该聚氨酯垫层厚度优选为10mm-20mm。根据场地的弹性需求,客户可以选择不同的厚度的聚氨酯垫层。当聚氨酯垫层厚度较小时,人造草坪垫层的弹性较低,减震性能较差;当聚氨酯垫层厚度较大时,人造草坪垫层的弹性较高,减震性能较好。本发明所制备的聚氨酯垫层厚度选为10-20mm,即保证了人造草坪垫层的回弹性能,也保证了人造草坪垫层的减震性能。
其中,实施例2的人造草坪垫层的加工流程主要包括:上胶-压紧-贴合-烘干;具体步骤如下:
将无毒无害无味的水性胶涂覆在聚氨酯垫层的一面上,采用贴合机将第一无纺布层压紧于涂覆有聚氨酯垫层的一面上,使第一无纺布层与聚氨酯垫层贴合于一起。其中,贴合时的温度为180-200℃,水性胶的使用量为每平方60-70 克。
实施例3:
一种人造草坪垫层,包括聚氨酯垫层2、第一无纺布层1和第二无纺布层3,如图1所示。其中,第一无纺布层1粘合于聚氨酯垫层2上表面,第二无纺布层3粘合于聚氨酯垫层2下表面。与实施例2相比,本实施中,上下两层无纺布层对聚氨酯垫层进行全方位保护,进一步增强了整个草坪垫层的抗撕裂能力。本实施例中,该聚氨酯垫层厚度优选为10-20mm。
其中,实施例3的人造草坪垫层的加工流程主要包括:上胶-压紧-贴合-烘干;具体步骤如下:
将无毒无害无味的水性胶涂覆在聚氨酯垫层的一面上,采用贴合机将其中一层无纺布层压紧于涂覆有聚氨酯垫层的一面上,使无纺布层与聚氨酯垫层贴合于一起。其中,贴合时的温度为180-200℃,水性胶的使用量为每平方60-70 克。另一层无纺布层按照同样的步骤贴合和聚氨酯垫层的另一面。
根据GB36246-2018《中小学合成材料面层运动场地》标准进行检测,上述实施例3的人造草坪垫层的相关性能如表2所示:
表2
如表2所示,含有聚氨酯垫层的人造草坪垫层其冲击吸收以及垂直变形性能均较好,即人在该草坪上运动时,足底、脚裸、膝盖等关节部位不容易受伤;其次,由于垂直变形较好,球落到草坪上回弹效果好,从而增强运动者的体验感。
此外,本发明主要采用回收的聚氨酯边角料制成的人造草坪垫层经过检测,不含任何挥发性有机物、重金属等,安全环保,无毒无害,符合运动场的安全标准。
上述实施方式仅为本发明的优选实施方式,不能以此来限定本发明保护的范围,本领域的技术人员在本发明的基础上所做的任何非实质性的变化及替换均属于本发明所要求保护的范围。
Claims (9)
1.一种聚氨酯垫层的加工工艺,其特征在于:包括以下步骤:
粉碎步骤:将回收的聚氨酯边角料倒入粉碎机中,粉碎成细小的聚氨酯颗粒;
筛选步骤:对所述粉碎步骤中细小的聚氨酯颗粒进行筛选,筛选出直径为2-5mm的聚氨酯颗粒;
混合步骤:将筛选出来的聚氨酯颗粒与聚氨酯粘合剂按10:1的比例加入搅拌机中搅拌均匀,倒入模具中;
发泡步骤:用运输带将模具运输至发泡箱中,将100-120℃蒸汽通入发泡箱中使混合物发泡定型,得到聚氨酯垫层半成品;其中,蒸汽通入时间为30-45min;
切割步骤:将聚氨酯垫层半成品置于自然状态下放置24-30小时,待垫层稳定后,对垫层进行切割修边,从而得到聚氨酯垫层。
2.如权利要求1所述的聚氨酯垫层的加工工艺,其特征在于:所述发泡步骤中,通入的蒸汽的温度为110℃。
3.一种人造草坪垫层,其特征在于:包括权利要求1或2所制备的聚氨酯垫层。
4.如权利要求3所述的人造草坪垫层,其特征在于:所述聚氨酯垫层为20mm。
5.如权利要求3所述的人造草坪垫层,其特征在于:还包括第一无纺布层,所述第一无纺布层粘合于所述聚氨酯垫层上表面。
6.如权利要求5所述的人造草坪垫层,其特征在于:所述聚氨酯垫层为10mm-20mm。
7.如权利要求5所述的人造草坪垫层,其特征在于:所述人造草坪垫层的加工流程具体如下:将无毒无害无味的水性胶涂覆在聚氨酯垫层的一面上,采用贴合机将第一无纺布层压紧于涂覆有聚氨酯垫层的一面上,使第一无纺布层与聚氨酯垫层贴合于一起;其中,贴合时的温度为180-200℃,水性胶的使用量为每平方60-70克。
8.如权利要求5所述的人造草坪垫层,其特征在于:还包括第二无纺布层,所述第二无纺布层粘合于所述聚氨酯垫层下表面。
9.如权利要求8所述的人造草坪垫层,其特征在于:所述聚氨酯垫层为10mm-20mm。
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