WO2007061163A1 - Manufacturing method for emitting negative ion and ultrared foamy rubber fabric and material thereof - Google Patents

Manufacturing method for emitting negative ion and ultrared foamy rubber fabric and material thereof Download PDF

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Publication number
WO2007061163A1
WO2007061163A1 PCT/KR2006/001469 KR2006001469W WO2007061163A1 WO 2007061163 A1 WO2007061163 A1 WO 2007061163A1 KR 2006001469 W KR2006001469 W KR 2006001469W WO 2007061163 A1 WO2007061163 A1 WO 2007061163A1
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Prior art keywords
approximately
weight parts
chloroprene
respect
foamy
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PCT/KR2006/001469
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French (fr)
Inventor
Young Hye Min
Joo Min Park
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Young Hye Min
Joo Min Park
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Application filed by Young Hye Min, Joo Min Park filed Critical Young Hye Min
Publication of WO2007061163A1 publication Critical patent/WO2007061163A1/en

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    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
    • C08J9/04—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent
    • C08J9/06—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent by a chemical blowing agent
    • C08J9/10—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent by a chemical blowing agent developing nitrogen, the blowing agent being a compound containing a nitrogen-to-nitrogen bond
    • C08J9/102—Azo-compounds
    • C08J9/103—Azodicarbonamide
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L15/00—Compositions of rubber derivatives
    • C08L15/02—Rubber derivatives containing halogen
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B25/00—Layered products comprising a layer of natural or synthetic rubber
    • B32B25/02—Layered products comprising a layer of natural or synthetic rubber with fibres or particles being present as additives in the layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B25/00—Layered products comprising a layer of natural or synthetic rubber
    • B32B25/10—Layered products comprising a layer of natural or synthetic rubber next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B25/00—Layered products comprising a layer of natural or synthetic rubber
    • B32B25/16—Layered products comprising a layer of natural or synthetic rubber comprising polydienes homopolymers or poly-halodienes homopolymers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B33/00—Layered products characterised by particular properties or particular surface features, e.g. particular surface coatings; Layered products designed for particular purposes not covered by another single class
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
    • C08J9/16—Making expandable particles
    • C08J9/18—Making expandable particles by impregnating polymer particles with the blowing agent
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K3/00—Use of inorganic substances as compounding ingredients
    • C08K3/18—Oxygen-containing compounds, e.g. metal carbonyls
    • C08K3/20—Oxides; Hydroxides
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K3/00—Use of inorganic substances as compounding ingredients
    • C08K3/34—Silicon-containing compounds
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/10—Inorganic particles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/10—Inorganic particles
    • B32B2264/101—Glass
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/10—Inorganic particles
    • B32B2264/107—Ceramic
    • B32B2264/108—Carbon, e.g. graphite particles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B32B2266/0207—Materials belonging to B32B25/00
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/02—Cellular or porous
    • B32B2305/022—Foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/10—Fibres of continuous length
    • B32B2305/18—Fabrics, textiles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/30—Fillers, e.g. particles, powders, beads, flakes, spheres, chips
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/304—Insulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/54—Yield strength; Tensile strength
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/582—Tearability
    • B32B2307/5825—Tear resistant
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2319/00—Synthetic rubber
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2437/00—Clothing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2535/00—Medical equipment, e.g. bandage, prostheses, catheter
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/12—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B82—NANOTECHNOLOGY
    • B82Y—SPECIFIC USES OR APPLICATIONS OF NANOSTRUCTURES; MEASUREMENT OR ANALYSIS OF NANOSTRUCTURES; MANUFACTURE OR TREATMENT OF NANOSTRUCTURES
    • B82Y30/00—Nanotechnology for materials or surface science, e.g. nanocomposites
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2311/00—Characterised by the use of homopolymers or copolymers of chloroprene

Definitions

  • the present invention relates to a foamy rubber fabric emitting negative ions and ultrared ray and a manufacturing method thereof, and more particularly, to a foamy rubber fabric and a manufacturing method thereof, wherein the foamy rubber fabric includes typical synthetic rubber with vacuum glass bubbles, which have excellent warmth retentivity and are light, and allows an adhesive, used to coat fibers on the surface of foamy rubber, to contain powder emitting negative ions and ultrared ray while maintaining a high level of tear strength using carbon nanotubes.
  • ultrared ray In addition to the negative ions, many people are increasingly interested in ultrared ray, which is beneficial to a human body. Generally, ultrared ray tends to be converted into thermal energy when being irradiated and absorbed into a substance. Thus, ultrared ray is applied to various fields including fabrics, clothes and bedding products to provide cozy and warm feelings, or to medical instruments to give a warm-blood effect advantageous for muscle aches and joint pains.
  • a material that emits the above mentioned negative ions and ultrared ray is included into synthetic rubber to form foamy rubber, which is already known in the art.
  • Ju-Min Park who is the applicant of this PCT application, teaches one exemplary foamy rubber in Korean Patent application, entitled “Foam rubber and Method for Manufacturing the Same” and filed with Korean Intellectual Property Office and published with KR 10-2003-0061112.
  • the typical foamy rubber is obtained via a plasticity process, which forms a mixture in a certain shape by passing through an extruder.
  • the mixture includes 3 to 10 weight parts of a glass bubble with a certain grain size with respect to 100 weight parts of a rubber component, 3 to 10 weight parts of ceramic with respect to 100 weight parts of chloroprene and 30 to 60 weight parts of a mixing agent with respect to 100 weight parts of chloroprene.
  • the glass bubble provides an insulation function, and the ceramic is one selected from a natural stone and coal emitting negative ions and ultrared ray.
  • the mixing agent discharges a foaming gas and serves a role in improving elasticity, wear resistance, and a ultrared ray emission characteristic.
  • the method includes: mixing a rubber component with a mixing agent in a certain ratio, wherein the mixing agent is obtained by mixing a ceramic component with a certain grain size selected from a natural stone and coal emitting negative ions and ultrared ray, a glass bubble with a certain grain size to improve warmth retentivity, a foaming agent discharging a foaming gas to improve elasticity, wear resistance and an ultrared emission characteristic, and an additive with each other; passing a mixture, obtained by mixing the rubber component and the mixing agent with each other, through an extruder to remove foreign materials and foams within the mixture and form the mixture in a certain shape; putting the mixture into a presser and heating and pressurizing the mixture to make the foaming agent foamed to thereby obtain foamy rubber.
  • the mixing agent is obtained by mixing a ceramic component with a certain grain size selected from a natural stone and coal emitting negative ions and ultrared ray, a glass bubble with a certain grain size to improve warmth retentivity, a foaming agent discharging a
  • the foamy rubber obtained based on the above described typical method may have a limitation in that the powder distributed within the foamy rubber is not uniformly distributed or is often distributed into a deep region. As a result, amounts of emitted negative ions and ultrared ray may be regionally different from each other and the actually obtained amounts thereof may not be close to the expected amounts.
  • vacuum glass bubbles are used to increase warmth retentivity, and a mixing ratio of the vacuum glass bubble may not be in an appropriate level. Hence, an appropriate level of warmth retentivity may not be retained. Disclosure of Invention Technical Problem
  • an object of the present invention is to provide a foamy rubber fabric including an adhesive used for adhering a fabric to foamy rubber and containing a material emitting negative ions and ultrared ray to increase an emission effect of negative ions and ultrared ray.
  • Another object of the present invention is to provide an appropriate mixing ratio of a glass bubble to increase warmth retentivity and decrease the weight of a foamy rubber fabric.
  • Another object of the present invention is to provide an appropriate mixing ratio of a carbon nanotube to allow foamy rubber to retain a high level of tear strength by using the carbon nanotube.
  • a further another object of the present invention is to provide a method for manu- factoring a foamy rubber fabric with an improved emission effect of negative ions and ultrared ray.
  • a foamy rubber fabric including foamy rubber, an adhesive and a fabric adhered to the surface of the foamy rubber using the adhesive.
  • the foamy rubber may include certain weight parts of magnesium oxide, zinc oxide, stearic acid, process oil, carbon, carbon nanotubes, light carcium carbonate, vacuum glass bubbles, an antioxidant, paraffin wax, a stimulant, and a foaming agent with respect to approximately 100 weight parts of chloroprene.
  • the adhesive may include a mixture containing certain weight parts of ultrared ray emitting powder, negative ion emitting powder and antibacterial powder with respect to approximately 100 weight parts of chloroprene with each other and coated on the surface of the foamy rubber.
  • a method for manufacturing a foamy rubber fabric including: a first mixing operation of mixing materials for forming foamy rubber including chloroprene with each other to provide a mixture; a first maturation operation of maturing the mixture at room temperature for approximately 24 hours; an extrusion processing operation of processing the matured mixture in a plate shape; a cutting operation of cutting the plate shaped mixture; a foaming operation of putting the cut mixture into a preheated presser and heating and pressurizing the cut mixture to foam azodicarbonamide serving as the foaming agent to thereby form foamy rubber; a second maturation operation of maturing the foamy rubber at room temperature for at least approximately 48 hours; a second mixing operation of mixing materials for an adhesive including negative ion emitting powder, ultrared ray emitting powder and antibacterial powder with the prepared chloroprene to obtain another mixture and maturing the other mixture for approximately 24 hours; an adhesional joining operation of coating the adhesive provided from the second mixing operation on the surface of
  • FlG. 1 is a cross-sectional view illustrating a foamy rubber fabricmanufactured according to an exemplary embodiment of the present invention
  • FlG. 2 is a flowchart illustrating sequential operations of a method for manufacturing a foamy rubber fabric according to an exemplary embodiment of the present invention
  • FlG. 3 is an enlarged view illustrating vacuum glass bubbles employed according to an exemplary embodiment of the present invention.
  • FlG. 4 illustrates enlarged scanning electron microscope (SEM) view of foamy rubber fabrics manufactured according to the exemplary embodiment of the present invention. Best Mode for Carrying Out the Invention
  • the foamy rubber 100 includes approximately 5 weight parts of magnesium oxide with respect to approximately 100 weight parts of chloroprene (synthetic rubber), approximately 5 weight parts of zinc oxide with respect to approximately 100 weight parts of chloroprene, approximately 2 weight parts of stearic acid with respect to approximately 100 weight parts of chloroprene, approximately 50 weight parts of process oil with respect to approximately 100 weight parts of chloroprene, approximately 10 weight parts of carbon with respect to approximately 100 weight parts of chloroprene, approximately 5 weight parts of carbon nanotubes with respect to approximately 100 weight parts of chloroprene, approximately 40 weight parts of light carcium carbonate with respect to approximately 100 weight parts of chloroprene, approximately 8 weight parts of vacuum glass bubbles with respect to approximately 100 weight parts of chloroprene, approximately 1 weight part of an antioxidant with respect to approximately 100 weight parts of chloroprene, approximately 5 weight parts
  • the adhesive 200 is prepared by mixing approximately 2.5 weight parts of ultrared ray emitting powder with respect to approximately 100 weight parts of chloroprene, approximately 6 weight parts of negative ion emitting powder with respect to approximately 100 weight parts of chloroprene and approximately 0.5 weight parts of antibacterial powder with respect to approximately 100 weight parts of chloroprene with each other and melting the mixture.
  • the fabric 300 is adhered to the surface of the foamy rubber 100 using the adhesive 200.
  • the magnesium oxide, zinc oxide and stearic acid are used as an activator, and the process oil and carbon are used as a softener and a reinforcing agent, respectively.
  • the antibacterial powder may be zeolite coated with silver.
  • the materials that can emit negative ions and ultrared ray are mixed with a natural stone of a rare earth element, which is often used to increase an amount of generating negative ions. Table 1 below shows the composition of the mixture.
  • the materials existing in power form with the above composition are injected into the adhesive 200. Although a part of the materials can be put into the materials for forming the foamy rubber 100, the specific gravity of these mixed materials becomes large. Thus, the powdery materials emitting negative ions and ultrared ray often lean to one side or are not distributed uniformly. These adverse effects may result in decrease of an emission level of negative ions and ultrared ray. Accordingly, in the present embodiment, the materials in power form are formed on the surface of the foamy rubber 100 with the adhesive 200 to allow emission of negative ions and ultrared rays directly through the fabric 300.
  • the vacuum glass bubbles are typically manufactured in Russia and United States.
  • the vacuum glass bubbles are developed to protect a spacecraft against heat generated by friction when the spacecraft enters into the atmosphere.
  • the vacuum glass bubbles have an excellent heat protection function but has an empty inner space.
  • the vacuum glass bubbles are formed in bubbles having an extremely low level of specific gravity.
  • the method includes a first mixing operation 10, a first maturation operation 20, an extrusion processing operation 30, a cutting operation 40, a foaming operation 50, a second maturation operation 60, a second mixing operation 70, and an adhesional joining operation 80.
  • the first mixing operation 10 the above mentioned materials such as chloroprene are mixed together.
  • the first maturation operation 20 the mixture is matured at room temperature for approximately 24 hours. After the first maturation operation 20, the mixture is processed in a plate shape in the extrusion processing operation 30, and the plate shaped mixture is cut in the cutting operation 40.
  • the cut mixture is put into a preheated presser and is heated and pressurized to foam the foaming agent such as azodicarbonamide, so that foamy rubber is generated in the foaming operation 50.
  • the foamed foamy rubber 100 is matured at room temperature for at least approximately 48 hours in the second maturation operation 60.
  • negative ion emitting powder, ultrared ray emitting powder and antibacterial power are mixed together with chloroprene and matured for approximately 24 hours to form the adhesive 200.
  • the adhesive 200 obtained after the second mixing operation 70 is coated over the surface of the foamy rubber 100 obtained after the second maturation operation (60) to be joined with the fabric 300.
  • the source material used in the first mixing operation 10 for forming the foamy rubber 100 may include approximately 5 weight parts of magnesium oxide with respect to approximately 100 parts of chloroprene (synthetic rubber), approximately 5 weight parts of zinc oxide with respect to approximately 100 parts of chloroprene, approximately 2 weight parts of stearic acid with respect to approximately 100 weight parts of chloroprene, approximately 50 weight parts of process oil with respect to approximately 100 weight parts of chloroprene, approximately 10 weight parts of carbon with respect to approximately 100 weight parts of chloroprene, approximately 5 weight parts of carbon nanotubes with respect to approximately 100 weight parts of chloroprene, approximately 40 weight parts of light carcium carbonate with respect to approximately 100 weight parts of chloroprene, approximately 8 weight parts of vacuum glass bubbles with respect to approximately 100 weight parts of chloroprene, approximately 1 weight part of an antioxidant with respect to approximately 100 weight parts of chloroprene, approximately 5 weight parts of paraffin wax with respect to approximately 100 weight parts of chloroprene, approximately 1 weight part of a
  • the adhesive 200 prepared in the second mixing operation 70 includes approximately 2.5 weight parts of ultrared ray emitting powder with respect to approximately 100 weight parts of chloroprene, approximately 6 weight parts of negative ion emitting powder with respect to approximately 100 weight parts of chloroprene and approximately 0.5 weight parts of antibacterial powder with respect to approximately 100 weight parts of chloroprene.
  • the carbon nanotube is a recently developed material manufactured and sold by JEIO Co., Ltd.
  • experimental results of a sample of a foamy rubber fabric manufactured according to the exemplary embodiment will be described. Particularly, warmth retentivity and amounts of generated negative ions of the sample will be examined.
  • FIG. 4 illustrates enlarged SEM views of a structure of the sample of the foamy rubber fabric manufactured according to the exemplary embodiment of the present invention. It can be verified that white balls, each with a diameter of approximately 3 mm, are vacuum glass bubbles.
  • Table 2 shows the test results on thermal conductivity of the foamy rubber fabric performed by Korean Textile Inspection and Testing Institute (KOTITI). [37] Table 2
  • the foamy rubber fabric according to the exemplary embodiment of the present invention gives the warmth retentivity substantially the same as the typical foamy rubber fabric having a thickness of approximately 5.5 mm.
  • the thickness of the embodied foamy rubber fabric is smaller than that of the typical foamy rubber fabric for maintaining substantially the same level of warmth retentivity, products with an excellent fitting feeling can be manufactured.
  • Table 3 shows test results of measurement on emission amounts of negative ions and ultrared ray of the embodied foamy rubber fabric.
  • the emission amount of the ultrared ray from the foamy rubber fabric according to the present embodiment is not different from the emission amount of the ultrared ray from the typical foamy rubber fabric at the same condition.
  • the emission amount of the negative ions from the embodied foamy rubber fabric is larger than the emission amount of the negative ions from the typical foamy rubber fabric by at least 6-fold.

Abstract

A foamy rubber fabric emitting negative ions and ultrared ray and a manufacturing method thereof are provided. The foamy rubber fabric includes synthetic rubber with vacuum glass bubbles and an adhesive, used to coat a fabric on the surface of the foamy rubber and containing powder emitting negative ions and ultrared ray, while maintaining high tear strength using carbon nanotubes. The vacuum glass bubbles and carbon nanotubes are mixed with a foamy rubber fabric to increase warmth retentivity and tear strength at the same thickness, and negative ion and ultrared ray emitting powdery materials are injected into the adhesive to increase emission amounts at the same condition. The maximization of the emission effect allows manufacturing of fabric products beneficial to a human body. Using the vacuum glass bubbles can increase warmth retentivity, thereby manufacturing fabric products that are light yet can provide the same warmth retentivity.

Description

Description
MANUFACTURING METHOD FOR EMITTING NEGATIVE ION AND ULTRARED FOAMY RUBBER FABRIC AND
MATERIAL THEREOF
Technical Field
[1] The present invention relates to a foamy rubber fabric emitting negative ions and ultrared ray and a manufacturing method thereof, and more particularly, to a foamy rubber fabric and a manufacturing method thereof, wherein the foamy rubber fabric includes typical synthetic rubber with vacuum glass bubbles, which have excellent warmth retentivity and are light, and allows an adhesive, used to coat fibers on the surface of foamy rubber, to contain powder emitting negative ions and ultrared ray while maintaining a high level of tear strength using carbon nanotubes.
Background Art
[2] As industrialization is becoming accelerated and environmental pollution is becoming severe, negative ions are increasingly highlighted due to their numerous benefits. If lots of negative ions exist in the air, various physiological actions of a human body become activated and immunity, which is a natural self-curing system, becomes improved. Also, negative ions activate cellular activities.
[3] In addition to the negative ions, many people are increasingly interested in ultrared ray, which is beneficial to a human body. Generally, ultrared ray tends to be converted into thermal energy when being irradiated and absorbed into a substance. Thus, ultrared ray is applied to various fields including fabrics, clothes and bedding products to provide cozy and warm feelings, or to medical instruments to give a warm-blood effect advantageous for muscle aches and joint pains.
[4] A material that emits the above mentioned negative ions and ultrared ray is included into synthetic rubber to form foamy rubber, which is already known in the art. For instance, Ju-Min Park, who is the applicant of this PCT application, teaches one exemplary foamy rubber in Korean Patent application, entitled "Foam rubber and Method for Manufacturing the Same" and filed with Korean Intellectual Property Office and published with KR 10-2003-0061112.
[5] The typical foamy rubber is obtained via a plasticity process, which forms a mixture in a certain shape by passing through an extruder. The mixture includes 3 to 10 weight parts of a glass bubble with a certain grain size with respect to 100 weight parts of a rubber component, 3 to 10 weight parts of ceramic with respect to 100 weight parts of chloroprene and 30 to 60 weight parts of a mixing agent with respect to 100 weight parts of chloroprene. The glass bubble provides an insulation function, and the ceramic is one selected from a natural stone and coal emitting negative ions and ultrared ray. The mixing agent discharges a foaming gas and serves a role in improving elasticity, wear resistance, and a ultrared ray emission characteristic. As for the method for manufacturing the typical foamy rubber, the method includes: mixing a rubber component with a mixing agent in a certain ratio, wherein the mixing agent is obtained by mixing a ceramic component with a certain grain size selected from a natural stone and coal emitting negative ions and ultrared ray, a glass bubble with a certain grain size to improve warmth retentivity, a foaming agent discharging a foaming gas to improve elasticity, wear resistance and an ultrared emission characteristic, and an additive with each other; passing a mixture, obtained by mixing the rubber component and the mixing agent with each other, through an extruder to remove foreign materials and foams within the mixture and form the mixture in a certain shape; putting the mixture into a presser and heating and pressurizing the mixture to make the foaming agent foamed to thereby obtain foamy rubber.
[6] However, since the material emitting negative ions and ultrared ray is formed in powder and is stirred with the rubber component, the foamy rubber obtained based on the above described typical method may have a limitation in that the powder distributed within the foamy rubber is not uniformly distributed or is often distributed into a deep region. As a result, amounts of emitted negative ions and ultrared ray may be regionally different from each other and the actually obtained amounts thereof may not be close to the expected amounts.
[7] Although the vacuum glass bubbles are used to increase warmth retentivity, and a mixing ratio of the vacuum glass bubble may not be in an appropriate level. Hence, an appropriate level of warmth retentivity may not be retained. Disclosure of Invention Technical Problem
[8] Therefore, in order to solve the problem of the related art, an object of the present invention is to provide a foamy rubber fabric including an adhesive used for adhering a fabric to foamy rubber and containing a material emitting negative ions and ultrared ray to increase an emission effect of negative ions and ultrared ray.
[9] Another object of the present invention is to provide an appropriate mixing ratio of a glass bubble to increase warmth retentivity and decrease the weight of a foamy rubber fabric.
[10] Another object of the present invention is to provide an appropriate mixing ratio of a carbon nanotube to allow foamy rubber to retain a high level of tear strength by using the carbon nanotube.
[11] A further another object of the present invention is to provide a method for manu- factoring a foamy rubber fabric with an improved emission effect of negative ions and ultrared ray. Technical Solution
[12] To achieve the above objects, there is provided a foamy rubber fabric, including foamy rubber, an adhesive and a fabric adhered to the surface of the foamy rubber using the adhesive. The foamy rubber may include certain weight parts of magnesium oxide, zinc oxide, stearic acid, process oil, carbon, carbon nanotubes, light carcium carbonate, vacuum glass bubbles, an antioxidant, paraffin wax, a stimulant, and a foaming agent with respect to approximately 100 weight parts of chloroprene. The adhesive may include a mixture containing certain weight parts of ultrared ray emitting powder, negative ion emitting powder and antibacterial powder with respect to approximately 100 weight parts of chloroprene with each other and coated on the surface of the foamy rubber.
[13] According to another embodiment of the present invention, there is provided a method for manufacturing a foamy rubber fabric, including: a first mixing operation of mixing materials for forming foamy rubber including chloroprene with each other to provide a mixture; a first maturation operation of maturing the mixture at room temperature for approximately 24 hours; an extrusion processing operation of processing the matured mixture in a plate shape; a cutting operation of cutting the plate shaped mixture; a foaming operation of putting the cut mixture into a preheated presser and heating and pressurizing the cut mixture to foam azodicarbonamide serving as the foaming agent to thereby form foamy rubber; a second maturation operation of maturing the foamy rubber at room temperature for at least approximately 48 hours; a second mixing operation of mixing materials for an adhesive including negative ion emitting powder, ultrared ray emitting powder and antibacterial powder with the prepared chloroprene to obtain another mixture and maturing the other mixture for approximately 24 hours; an adhesional joining operation of coating the adhesive provided from the second mixing operation on the surface of the foamy rubber provided after the second maturation operation and joining a fabric with the adhesive coated foamy rubber. Advantageous Effects
[14] As described above, exemplary embodiments of the present invention are advantageous as follows.
[15] Since various useful effects provided by negative ions and ultrared ray can be maximized, fabric products beneficial to a human body can be manufactured.
[16] Using vacuum glass bubbles allows manufacturing of fabrics with high warmth re- tentivity, and thus, products that are thin yet have substantially the same level of warmth retentivity as the typical ones can be manufactured. [17] Also, products with an increased level of mechanical strength such as tensile strength, tear strength and a compressed permanent fold ratio can be manufactured through employing carbon nanotubes.
Brief Description of the Drawings
[18] FlG. 1 is a cross-sectional view illustrating a foamy rubber fabricmanufactured according to an exemplary embodiment of the present invention;
[19] FlG. 2 is a flowchart illustrating sequential operations of a method for manufacturing a foamy rubber fabric according to an exemplary embodiment of the present invention;
[20] FlG. 3 is an enlarged view illustrating vacuum glass bubbles employed according to an exemplary embodiment of the present invention; and
[21] FlG. 4 illustrates enlarged scanning electron microscope (SEM) view of foamy rubber fabrics manufactured according to the exemplary embodiment of the present invention. Best Mode for Carrying Out the Invention
[22] Various exemplary embodiments of the present invention will be described in detail with reference to the accompanying drawings.
[23] As illustrated in FIGS. 1 through 4, a foamy rubber 100, an adhesive 200 and a fabric 300 are provided according to an exemplary embodiment of the present invention. The foamy rubber 100 includes approximately 5 weight parts of magnesium oxide with respect to approximately 100 weight parts of chloroprene (synthetic rubber), approximately 5 weight parts of zinc oxide with respect to approximately 100 weight parts of chloroprene, approximately 2 weight parts of stearic acid with respect to approximately 100 weight parts of chloroprene, approximately 50 weight parts of process oil with respect to approximately 100 weight parts of chloroprene, approximately 10 weight parts of carbon with respect to approximately 100 weight parts of chloroprene, approximately 5 weight parts of carbon nanotubes with respect to approximately 100 weight parts of chloroprene, approximately 40 weight parts of light carcium carbonate with respect to approximately 100 weight parts of chloroprene, approximately 8 weight parts of vacuum glass bubbles with respect to approximately 100 weight parts of chloroprene, approximately 1 weight part of an antioxidant with respect to approximately 100 weight parts of chloroprene, approximately 5 weight parts of paraffin wax with respect to approximately 100 weight parts of chloroprene, approximately 1 weight part of a stimulant 22 with respect to approximately 100 weight parts of chloroprene, and approximately 10 weight parts of a foaming agent with respect to approximately 100 weight parts of chloroprene. The adhesive 200 is prepared by mixing approximately 2.5 weight parts of ultrared ray emitting powder with respect to approximately 100 weight parts of chloroprene, approximately 6 weight parts of negative ion emitting powder with respect to approximately 100 weight parts of chloroprene and approximately 0.5 weight parts of antibacterial powder with respect to approximately 100 weight parts of chloroprene with each other and melting the mixture. The fabric 300 is adhered to the surface of the foamy rubber 100 using the adhesive 200.
[24] The magnesium oxide, zinc oxide and stearic acid are used as an activator, and the process oil and carbon are used as a softener and a reinforcing agent, respectively.
[25] The antibacterial powder may be zeolite coated with silver. [26] The materials that can emit negative ions and ultrared ray are mixed with a natural stone of a rare earth element, which is often used to increase an amount of generating negative ions. Table 1 below shows the composition of the mixture.
[27] Table 1
Figure imgf000006_0001
[28] The materials existing in power form with the above composition are injected into the adhesive 200. Although a part of the materials can be put into the materials for forming the foamy rubber 100, the specific gravity of these mixed materials becomes large. Thus, the powdery materials emitting negative ions and ultrared ray often lean to one side or are not distributed uniformly. These adverse effects may result in decrease of an emission level of negative ions and ultrared ray. Accordingly, in the present embodiment, the materials in power form are formed on the surface of the foamy rubber 100 with the adhesive 200 to allow emission of negative ions and ultrared rays directly through the fabric 300.
[29] The vacuum glass bubbles are typically manufactured in Russia and United States. The vacuum glass bubbles are developed to protect a spacecraft against heat generated by friction when the spacecraft enters into the atmosphere. Although the vacuum glass bubbles have an excellent heat protection function but has an empty inner space. Hence, the vacuum glass bubbles are formed in bubbles having an extremely low level of specific gravity.
[30] As for a method for manufacturing a foamy rubber fabric according to an exemplary embodiment of the present invention, the method includes a first mixing operation 10, a first maturation operation 20, an extrusion processing operation 30, a cutting operation 40, a foaming operation 50, a second maturation operation 60, a second mixing operation 70, and an adhesional joining operation 80. In the first mixing operation 10, the above mentioned materials such as chloroprene are mixed together. In the first maturation operation 20, the mixture is matured at room temperature for approximately 24 hours. After the first maturation operation 20, the mixture is processed in a plate shape in the extrusion processing operation 30, and the plate shaped mixture is cut in the cutting operation 40. The cut mixture is put into a preheated presser and is heated and pressurized to foam the foaming agent such as azodicarbonamide, so that foamy rubber is generated in the foaming operation 50. The foamed foamy rubber 100 is matured at room temperature for at least approximately 48 hours in the second maturation operation 60. In the second mixing operation 70, negative ion emitting powder, ultrared ray emitting powder and antibacterial power are mixed together with chloroprene and matured for approximately 24 hours to form the adhesive 200. In the adhesional joining operation 80, the adhesive 200 obtained after the second mixing operation 70 is coated over the surface of the foamy rubber 100 obtained after the second maturation operation (60) to be joined with the fabric 300.
[31] The source material used in the first mixing operation 10 for forming the foamy rubber 100 may include approximately 5 weight parts of magnesium oxide with respect to approximately 100 parts of chloroprene (synthetic rubber), approximately 5 weight parts of zinc oxide with respect to approximately 100 parts of chloroprene, approximately 2 weight parts of stearic acid with respect to approximately 100 weight parts of chloroprene, approximately 50 weight parts of process oil with respect to approximately 100 weight parts of chloroprene, approximately 10 weight parts of carbon with respect to approximately 100 weight parts of chloroprene, approximately 5 weight parts of carbon nanotubes with respect to approximately 100 weight parts of chloroprene, approximately 40 weight parts of light carcium carbonate with respect to approximately 100 weight parts of chloroprene, approximately 8 weight parts of vacuum glass bubbles with respect to approximately 100 weight parts of chloroprene, approximately 1 weight part of an antioxidant with respect to approximately 100 weight parts of chloroprene, approximately 5 weight parts of paraffin wax with respect to approximately 100 weight parts of chloroprene, approximately 1 weight part of a stimulant 22 with respect to approximately 100 weight parts of chloroprene, and approximately 10 weight parts of a foaming agent with respect to approximately 100 weight parts of chloroprene.
[32] The adhesive 200 prepared in the second mixing operation 70 includes approximately 2.5 weight parts of ultrared ray emitting powder with respect to approximately 100 weight parts of chloroprene, approximately 6 weight parts of negative ion emitting powder with respect to approximately 100 weight parts of chloroprene and approximately 0.5 weight parts of antibacterial powder with respect to approximately 100 weight parts of chloroprene.
[33] The carbon nanotube is a recently developed material manufactured and sold by JEIO Co., Ltd. [34] Hereinafter, experimental results of a sample of a foamy rubber fabric manufactured according to the exemplary embodiment will be described. Particularly, warmth retentivity and amounts of generated negative ions of the sample will be examined.
[35] FIG. 4 illustrates enlarged SEM views of a structure of the sample of the foamy rubber fabric manufactured according to the exemplary embodiment of the present invention. It can be verified that white balls, each with a diameter of approximately 3 mm, are vacuum glass bubbles.
[36] Table 2 below shows the test results on thermal conductivity of the foamy rubber fabric performed by Korean Textile Inspection and Testing Institute (KOTITI). [37] Table 2
Figure imgf000008_0001
[38] As shown, the foamy rubber fabric according to the exemplary embodiment of the present invention, particularly having a thickness of approximately 3.5 mm, gives the warmth retentivity substantially the same as the typical foamy rubber fabric having a thickness of approximately 5.5 mm. Thus, even though the thickness of the embodied foamy rubber fabric is smaller than that of the typical foamy rubber fabric for maintaining substantially the same level of warmth retentivity, products with an excellent fitting feeling can be manufactured.
[39] Table 3 below shows test results of measurement on emission amounts of negative ions and ultrared ray of the embodied foamy rubber fabric.
[40] Table 3
Figure imgf000009_0001
[41] The emission amount of the ultrared ray from the foamy rubber fabric according to the present embodiment is not different from the emission amount of the ultrared ray from the typical foamy rubber fabric at the same condition. However, the emission amount of the negative ions from the embodied foamy rubber fabric is larger than the emission amount of the negative ions from the typical foamy rubber fabric by at least 6-fold. Hence, products beneficial to a human body can be manufactured.
[42] Although the exemplary embodiments of the present invention are described with reference to the accompanying drawings, the present invention should not construed as being limited to the provided exemplary embodiments and the drawings, and it will be understood by those of ordinary skill in the art that various changes in form and details may be made without departing from the spirit and scope of the present invention.

Claims

Claims
[1] A foamy rubber fabric obtained by preparing foamy rubber using chloroprene as a main material, coating an adhesive on the surface of the foamy rubber and adhering a fabric to the adhesive coated foamy rubber, the foamy rubber comprising: a mixture including approximately 2.5 weight parts of ultrared ray emitting powder with respect to approximately 100 weight parts of chloroprene, approximately 6 weight parts of negative ion emitting powder with respect to approximately 100 weight parts of chloroprene and approximately 0.5 weight parts of antibacterial powder with respect to approximately 100 weight parts of chloroprene and mixed with the adhesive.
[2] The foamy rubber fabric of claim 1, wherein the foamy rubber includes approximately 5 weight parts of magnesium oxide with respect to approximately 100 weight parts of chloroprene being synthetic rubber, approximately 5 weight parts of zinc oxide with respect to approximately 100 weight parts of chloroprene, approximately 2 weight parts of stearic acid with respect to approximately 100 weight parts of chloroprene, approximately 50 weight parts of process oil with respect to approximately 100 weight parts of chloroprene, approximately 10 weight parts of carbon with respect to approximately 100 weight parts of chloroprene, approximately 5 weight parts of carbon nanotubes with respect to approximately 100 weight parts of chloroprene, approximately 40 weight parts of light carcium carbonate with respect to approximately 100 weight parts of chloroprene, approximately 8 weight parts of vacuum glass bubbles with respect to approximately 100 weight parts of chloroprene, approximately 1 weight part of an antioxidant with respect to approximately 100 weight parts of chloroprene, approximately 5 weight parts of paraffin wax with respect to approximately 100 weight parts of chloroprene, approximately 1 weight part of a stimulant 22 with respect to approximately 100 weight parts of chloroprene, and approximately 10 weight parts of a foaming agent with respect to approximately 100 weight parts of chloroprene.
[3] The foamy rubber fabric of claim 1 or 2, wherein the ultrared ray emitting powder includes a natural stone of a rare earth element.
[4] The foamy rubber fabric of claim 1 or 2, wherein the antibacterial powder includes zeolite coated with silver.
[5] A method for manufacturing a foamy rubber fabric, comprising: a first mixing operation (10) of mixing the materials for the foamy rubber claimed in claim 2 with each other to provide a mixture; a first maturation operation (20) of maturing the mixture at room temperature for approximately 24 hours; an extrusion processing operation (30) of processing the matured mixture in a plate shape; a cutting operation (40) of cutting the plate shaped mixture; a foaming operation (50) of putting the cut mixture into a preheated presser and heating and pressurizing the cut mixture to foam azodicarbonamide serving as the foaming agent to thereby form foamy rubber; a second maturation operation (60) of maturing the foamy rubber (100) at room temperature for at least approximately 48 hours; a second mixing operation (70) of mixing the materials for the adhesive claimed in claim 1 to obtain another mixture and maturing the other mixture for approximately 24 hours; and an adhesional joining operation (80) of coating the adhesive provided from the second mixing operation (70) on the surface of the foamy rubber provided after the second maturation operation (60) and joining a fabric with the adhesive coated foamy rubber.
PCT/KR2006/001469 2005-11-25 2006-04-20 Manufacturing method for emitting negative ion and ultrared foamy rubber fabric and material thereof WO2007061163A1 (en)

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