阅读说明：本技术 一种耐磨发泡汽车脚垫及制备方法 (Wear-resistant foamed automobile foot pad and preparation method thereof ) 是由 陈统照 于 2020-06-16 设计创作，主要内容包括：本发明属于汽车内饰用品领域,具体涉及一种耐磨发泡汽车脚垫及制备方法。利用乳胶易起泡的特性,将无机纤维分散其中,并添加起泡剂、硫化剂、抗氧化剂低速搅拌起泡,从而形成具有均匀闭孔细泡的发泡体,辅助一定量的胶凝剂,涂敷在亚麻基布,通过热蒸汽硫化,使发泡体硫化固化在亚麻基布形成发泡乳胶基垫；得到具有良好的回弹性和柔软舒适性的基垫；进一步的,将聚氨酯胶、硅酮粉、玻璃粉、陶瓷粉分散为喷涂液,喷涂在发泡体层,使发泡体具有良好的耐水性、自洁性、耐磨性。以此获得的汽车脚垫脚感舒适,耐磨、抗滑、耐水自洁,大幅提升汽车内饰装饰感和质感。(The invention belongs to the field of automotive interior articles, and particularly relates to a wear-resistant foamed automobile foot pad and a preparation method thereof. Dispersing inorganic fibers in latex by utilizing the characteristic of easy foaming of the latex, adding a foaming agent, a vulcanizing agent and an antioxidant, stirring at a low speed, foaming to form a foaming body with uniform closed-cell fine bubbles, assisting a certain amount of gelling agent, coating the foaming body on linen base cloth, and vulcanizing and curing the foaming body on the linen base cloth through hot steam vulcanization to form a foaming latex base pad; obtaining a base cushion with good rebound resilience, softness and comfort; furthermore, polyurethane glue, silicone powder, glass powder and ceramic powder are dispersed into spraying liquid and sprayed on the foaming body layer, so that the foaming body has good water resistance, self-cleaning property and wear resistance. The obtained automobile foot mat has comfortable foot feel, wear resistance, skid resistance, water resistance and self-cleaning property, and greatly improves the decoration feeling and texture of the interior decoration of the automobile.)

1. A preparation method of a wear-resistant foamed automobile foot pad is characterized by comprising the following steps:

(1) adding the latex, the inorganic fiber, the foaming agent, the vulcanizing agent and the antioxidant into a stirrer, stirring at the rotating speed of 40-50rpm for 5-10min to form uniform fine bubbles after the latex is foamed, then adding the gelling agent, and continuing stirring for 1-2min to obtain a foam containing the uniform fine bubbles;

(2) coating the foaming body obtained in the step (1) on flax woven base cloth in a blade coating thickness of 5-8mm, then sending the base cloth into a mold, setting the mold, which is a template with hemispherical concave points, for 3-5min for pre-solidification, then sending the mold into steam at 110 ℃ for vulcanization and solidification for 5-8min, naturally cooling, and opening the mold to obtain a foaming latex base pad;

(3) uniformly dispersing polyurethane glue, silicone powder, glass powder and ceramic powder to obtain wear-resistant glue, spraying the wear-resistant glue on the latex surface of the latex-based pad obtained in the step (2), and naturally drying and curing; hot-melting and coating the hot melt adhesive on a flax woven base cloth surface, and embossing by a press roller to form an adhesive nail anti-skid surface; obtaining the wear-resistant foamed automobile foot mat.

2. The method for preparing a wear-resistant foamed automobile foot mat according to claim 1, wherein the method comprises the following steps: the addition amount of the latex, the inorganic fiber, the foaming agent, the vulcanizing agent, the antioxidant and the gelling agent in the step (1) is as follows by weight: 60-70 parts of latex, 5-10 parts of inorganic fiber, 0.5-0.7 part of foaming agent, 0.2-0.3 part of vulcanizing agent, 0.1-0.3 part of antioxidant and 1-2 parts of gelling agent.

3. The method for preparing a wear-resistant foamed automobile foot mat according to claim 1, wherein the method comprises the following steps: the latex in the step (1) is formed by compounding natural latex with solid content of 40% and synthetic latex with solid content of 60% in a mass ratio of 4: 1; the inorganic fiber is selected from one of wollastonite fiber, glass fiber and magnesium hydroxide fiber; the foaming agent is carboxylate emulsifier RAYNOL PC-3930 provided by Qingdao Ruinoo chemical Co., Ltd; the vulcanizing agent is one of dicumyl peroxide and hydroxyl cumene peroxide; the antioxidant is selected from one of an antioxidant 1010 and an antioxidant 168; the gelling agent is citric acid.

4. The method for preparing a wear-resistant foamed automobile foot mat according to claim 1, wherein the method comprises the following steps: in the step (2), flax woven base cloth is used as a base material of the foot pad, and the gram weight of the flax woven base cloth is 180g/m²。

5. The method for preparing a wear-resistant foamed automobile foot mat according to claim 1, wherein the method comprises the following steps: the height of the concave points of the template with the hemispherical concave points in the step (2) is 2mm, and the caliber of the concave points is 3-5 mm.

6. The method for preparing a wear-resistant foamed automobile foot mat according to claim 1, wherein the method comprises the following steps: in the step (3), polyurethane adhesive, silicone powder, glass powder and ceramic powder are mixed according to a mass ratio of 100: 1-2:5-8:3-5, and dispersing uniformly.

7. The method for preparing a wear-resistant foamed automobile foot mat according to claim 1, wherein the method comprises the following steps: in the step (3), the solid content of the polyurethane adhesive is 15%; the glass powder and the ceramic powder are micro powder with the particle size of less than 20 mu m.

8. The method for preparing a wear-resistant foamed automobile foot mat according to claim 1, wherein the method comprises the following steps: the spraying thickness of the dispersion liquid consisting of the polyurethane glue, the silicone powder, the glass powder and the ceramic powder on the latex surface in the step (3) is 100-200 mu m.

9. The method for preparing a wear-resistant foamed automobile foot mat according to claim 1, wherein the method comprises the following steps: preferably, the hot melt adhesive in the step (3) is EVA; the coating thickness of the flax woven base cloth is 0.5-1 mm.

10. A wear-resistant foamed automotive foot mat obtained by the method of any one of claims 1 to 9.

Technical Field

The invention belongs to the field of automotive interior articles, and particularly relates to a wear-resistant foamed automobile foot pad and a preparation method thereof.

Background

As a conventional automobile interior decoration article, the automobile foot mat is a standard accessory of an automobile at present. The main purpose is to protect the car floor, isolate chassis noise, and have good comfort and durability. The automobile foot pad is used, so that the automobile foot pad is prevented from being used for dirtying the inside of the automobile, and the cleaning is convenient; on the other hand, the automobile foot pad is required to have good wear resistance, water resistance, dust resistance and skid resistance, and the driving safety is not influenced.

With the rapid development of the automobile industry in China, the automobile foot pad is gradually mature from the aspects of material selection, manufacturing process and the like. The automobile foot pad material mainly comprises a chemical fiber foot pad, a PVC foot pad, a rubber foot pad, a wire coil foot pad, a flax foot pad, a leather foot pad, a wool foot pad and the like. The chemical fiber foot pad is very dirty; although the flax foot pad is low in price and soft, the flax foot pad is easy to fluff and deform after being cleaned; the PVC foot pad is easy to clean, but easy to age and harden; the product is easy to harden in winter; the leather foot pad is convenient to clean, but has poor sound insulation effect; the rubber foot pad is convenient to clean, but not environment-friendly enough, and has heavy taste; the wool foot pad is high in cost and difficult to clean.

At present, in order to pursue the texture of travelling comfort, the callus on the sole chooses high-grade materials such as wool for use, and not only the clearance is difficult, and the antiskid nature is relatively poor moreover, can influence driving safety. The product has high quality and low price, meets the comfortable feeling of the foot pad and is urgently needed by the market at present. The Chinese patent publication No. CN 103897222A discloses a freely-cut coiled material for automobile foot pads and a manufacturing process thereof, wherein natural rubber, calcium carbonate and an accelerator are put into an internal mixer to be uniformly stirred, and then the mixture is put into a rubber mixing furnace; adding sulfur, stirring uniformly, and discharging from a rubber mixing furnace to form a thermoplastic elastic rubber sheet; and pressing the alternate concave-convex textures by the hot-pressing roller. This technology discloses the preparation of car foot mats using natural rubber, but fails to obtain foot mats with excellent cushioning feel.

The natural rubber as a rubber completely derived from biomass has great prospect in the application aspect of the automobile foot pad. Particularly, the natural rubber latex has the suitable rebound resilience which is applied to the aspects of latex mattresses and the like at present, and has stronger buffering texture. However, the natural latex solution is applied to the car foot pads less at present. The natural latex is improved and treated to be the foot pad which is rich in closed pores, wear-resistant, waterproof and self-cleaning, and has great potential in the aspects of improving the texture of the foot pad, improving the grade of automotive interior and ensuring safe driving.

Disclosure of Invention

The invention provides a wear-resistant foamed automobile foot mat and a preparation method thereof, and aims to solve the problems that the existing wool foot mat is difficult to clean, poor in safety, poor in comfort and poor in wear resistance of the foamed automobile foot mat. The method is fundamentally characterized in that the natural rubber latex is subjected to closed-cell bubble treatment, inorganic fiber is used for modification to form the foot pad with excellent resilience, and meanwhile, the wear-resistant foamed automobile foot pad is obtained by treatment of the wear-resistant coating.

In order to obtain good comfort and wear resistance of the foamed automobile foot pad, firstly, a preparation method of the wear-resistant foamed automobile foot pad is provided, and is characterized by comprising the following steps:

(1) adding the latex, the inorganic fiber, the foaming agent, the vulcanizing agent and the antioxidant into a stirrer, stirring at the rotating speed of 40-50rpm for 5-10min to form uniform fine bubbles after the latex is foamed, then adding the gelling agent, and continuing stirring for 1-2min to obtain a foam containing the uniform fine bubbles;

(2) coating the foaming body obtained in the step (1) on flax woven base cloth in a blade coating thickness of 5-8mm, then sending the base cloth into a mold, setting the mold, which is a template with hemispherical concave points, for 3-5min for pre-solidification, then sending the mold into steam at 110 ℃ for vulcanization and solidification for 5-8min, naturally cooling, and opening the mold to obtain a foaming latex base pad;

(3) uniformly dispersing polyurethane glue, silicone powder, glass powder and ceramic powder to obtain wear-resistant glue, spraying the wear-resistant glue on the latex surface of the latex-based pad obtained in the step (2), and naturally drying and curing; hot-melting and coating the hot melt adhesive on a flax woven base cloth surface, and embossing by a press roller to form an adhesive nail anti-skid surface; obtaining the wear-resistant foamed automobile foot mat.

In order to obtain good comfort and wear resistance of the foamed automobile foot pad, the latex, the inorganic fiber, the foaming agent, the vulcanizing agent and the antioxidant are stirred at a low speed to foam, so that a foaming body with uniform closed-cell fine bubbles is formed, a certain amount of gelling agent is assisted to be coated on the flax base cloth, and the foaming body is vulcanized and solidified on the flax base cloth through hot steam vulcanization to form the foamed latex base pad; the elastic rubber has good rebound resilience, softness and comfort; in particular, polyurethane glue, silicone powder, glass powder and ceramic powder are dispersed into spraying liquid and sprayed on a foaming body layer, so that the foaming body has good water resistance, self-cleaning property and wear resistance. The obtained automobile foot mat has comfortable foot feel, wear resistance, skid resistance, water resistance and self-cleaning property, and can greatly improve the decoration feeling and texture of the interior of the automobile.

Preferably, the latex, the inorganic fiber, the foaming agent, the vulcanizing agent, the antioxidant and the gelling agent in the step (1) are added in the following weight portions: 60-70 parts of latex, 5-10 parts of inorganic fiber, 0.5-0.7 part of foaming agent, 0.2-0.3 part of vulcanizing agent, 0.1-0.3 part of antioxidant and 1-2 parts of gelling agent.

Further preferably, the latex in the step (1) is formed by compounding natural latex with a solid content of 40% and synthetic latex with a solid content of 60% in a mass ratio of 4: 1. The natural latex is the juice generated by the rubber tree, and the natural latex is an elastic solid material after being subjected to crosslinking reaction and solidification, has good biomass characteristics and low allergen, and has excellent resilience, comfortable feeling and stable mechanical property. But the cost is higher, and the cost can be reasonably controlled by auxiliary synthesis of the latex. Preferably, the synthetic latex is styrene-butadiene latex.

Further preferably, the inorganic fiber in the step (1) is selected from one of wollastonite fiber, glass fiber and magnesium hydroxide fiber; the foam material is used for the foam body, not only reduces the cost, but also strongly supports the foam body, effectively prevents the foam body from collapsing and deforming in long-term use, and improves the wear resistance of the foam body.

Further preferably, the step (1) uses a foaming agent for the purpose of mixing the latex with air, thereby generating bubbles; surfactants such as soaps and the like can be selected as foaming agents, and a carboxylate emulsifier RAYNOL PC-3930 provided by Qingdao Ruinoo chemical Co., Ltd is selected as the foaming agent in the experiment; the foaming agent forms fine and uniform bubbles under low stirring, and the bubbles are closed pores; the fine and uniform closed pores not only ensure that the foam has good rebound buffering effect, but also can not absorb dirt, can not absorb water and is easy to clean.

Further preferably, the vulcanizing agent in the step (1) is dicumyl peroxide or cumyl hydroperoxide, which can promote the vulcanization and curing of the latex at a lower temperature.

Further preferably, the antioxidant in step (1) is selected from one of antioxidant 1010 and antioxidant 168.

The natural latex is a material which is easy to solidify when meeting acid, and after the natural latex is foamed, a certain proportion of acid substances are added as gelling agents, so that the latex and the pre-solidification can be realized, and stable bubbles are formed. Further preferably, the gelling agent in step (1) is citric acid. Since the latex gradually solidifies after the addition of citric acid, the gelling agent needs to be added after complete foaming, and the blade coating is carried out immediately after the addition of the gelling agent, otherwise the blade coating uniformity is affected once the gelling agent is solidified.

Preferably, the linen woven base cloth is used as the base material of the foot pad in the step (2). In principle, various nonwovens, PVC sheets and woven fabrics can be used as substrates for carrying the knife-coated foams. However, after the foam is coated by a knife coating, the foam needs to be crosslinked and vulcanized at the steam temperature of 110 ℃, and the linen woven base fabric is selected as the base material of the foot mat in consideration of the temperature bearing of the base material. Further, the gram weight of the flax woven base cloth is 180g/m²The obtained foot pad has good fusion and adherence with latex as a base material of the foot pad, and is not easy to degum after being washed.

Preferably, the blade coating thickness in the step (2) is 5-8mm, the coating is too thick, the cost is high, and the foot pad deformation is too large, which affects the accuracy of the driver in operating the brake, the accelerator and the like, so the blade coating foaming body is not too large in thickness. If the thickness is too small, the cushion elasticity is poor, and the comfort is impaired.

Preferably, the height of the pits of the template with the hemispherical pits in the step (2) is 2mm, and the caliber of the pits is 3-5 mm; the foaming body forms convex points through the concave point template, thereby having good skid resistance.

Preferably, in the step (3), the polyurethane adhesive, the silicone powder, the glass powder and the ceramic powder are mixed according to a mass ratio of 100: 1-2:5-8:3-5 are uniformly dispersed;

preferably, the solid content of the polyurethane adhesive in the step (3) is 15%, silicone powder, glass powder and ceramic powder are dispersed in the polyurethane adhesive and sprayed on the latex surface of the latex base pad, and a coating formed after natural drying and curing has good wear resistance, skid resistance and hydrophobic self-cleaning property; the silicone powder has excellent hydrophobicity, and is in a polyurethane coating in a powder form, so that the coating is endowed with hydrophobic self-cleaning property; the glass powder and the ceramic powder are micro powder with the grain diameter less than 20 mu m, and the wear resistance of the polyurethane coating is increased in the coating.

Further preferably, the spraying thickness of the dispersion liquid consisting of the polyurethane glue, the silicone powder, the glass powder and the ceramic powder on the latex surface in the step (3) is 100-200 μm, and the dispersion liquid is naturally dried; hot-melting and coating the hot melt adhesive on a flax woven base cloth surface, and embossing by a press roller to form an adhesive nail anti-skid surface; obtaining the wear-resistant foamed automobile foot mat.

Preferably, the hot melt adhesive in the step (3) is EVA which can be hot-melted at a lower temperature; the coating thickness of the flax woven base cloth is 0.5-1 mm; forming a non-slip surface of the rubber nail by embossing with a press roller; the surface is in direct contact with the ground of the vehicle, has good adhesion and effectively prevents the foot pad from sliding and walking.

Furthermore, the invention provides the wear-resistant foamed automobile foot pad prepared by the method. In order to obtain the comfortable, antiskid and wear-resistant automobile foot pad, inorganic fibers are dispersed in the automobile foot pad by utilizing the characteristic of easy foaming of latex, a foaming agent, a vulcanizing agent and an antioxidant are added to be stirred and foamed at a low speed, so that a foaming body with uniform closed-cell fine bubbles is formed, a certain amount of gelling agent is assisted to be coated on flax base cloth, and the foaming body is vulcanized and solidified on the flax base cloth through hot steam vulcanization to form a foaming latex base pad; obtaining a base cushion with good rebound resilience, softness and comfort; furthermore, polyurethane glue, silicone powder, glass powder and ceramic powder are dispersed into spraying liquid and sprayed on the foaming body layer, so that the foaming body has good water resistance, self-cleaning property and wear resistance. The obtained automobile foot mat has comfortable foot feel, wear resistance, skid resistance, water resistance and self-cleaning property, and greatly improves the decoration feeling and texture of the interior decoration of the automobile.

Compared with the prior art, the invention has the following excellent effects:

(1) dispersing inorganic fibers in latex by utilizing the characteristic of easy foaming of the latex, adding a foaming agent, a vulcanizing agent and an antioxidant, stirring at a low speed, foaming to form a foaming body with uniform closed-cell fine bubbles, assisting a certain amount of gelling agent, coating the foaming body on linen base cloth, and vulcanizing and curing the foaming body on the linen base cloth through hot steam vulcanization to form a foaming latex base pad; a base pad with good resilience and soft comfort is obtained.

(2) Polyurethane glue, silicone powder, glass powder and ceramic powder are dispersed into spraying liquid and sprayed on the foaming body layer, so that the foaming body has good water resistance, self-cleaning property and wear resistance.

(3) According to the invention, the latex is reasonably used for the automobile foot pad, the foot pad has excellent buffering property, wear resistance and water resistance through foaming and wear-resistant treatment, and is soft and textured when being stepped on, so that the effect of improving the quality of automobile interior decoration is remarkable, and the cost is not obviously increased.

Drawings

The invention is further described below with reference to the accompanying drawings:

FIG. 1 is a schematic view of a wear-resistant foamed car foot mat according to the present invention. Wherein: 1-weaving base cloth with flax; 2-glue nail; 3-latex foam; 4-wear-resistant glue layer.

Detailed Description

The present invention is further illustrated by the following examples, which are presently preferred and illustrative, but are not intended to limit the scope of the invention.