CN101961201B - 缓冲吸收垫 - Google Patents

缓冲吸收垫 Download PDF

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CN101961201B
CN101961201B CN201010176859.XA CN201010176859A CN101961201B CN 101961201 B CN101961201 B CN 101961201B CN 201010176859 A CN201010176859 A CN 201010176859A CN 101961201 B CN101961201 B CN 101961201B
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braided fabric
fabric material
layer
polyester
polyamide
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CN101961201A (zh
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I·斯科吉
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MINDSINSYNC
MindsInSync公司
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Abstract

一种缓冲吸水垫，包括一种吸水、速干的编织织物材料层；一种具有开放的蜂窝状构造的聚氨酯泡沫材料层，粘合且缝合到编织织物材料层以形成织物和泡沫体组件；以及一种粘合到织物和泡沫组件中的泡沫材料这一面的经涂胶的基础材料层。

Description

缓冲吸收垫
技术领域
本发明大致涉及一种垫子，更具体地说，涉及一种具有吸收性表面和缓冲层的垫子。
背景技术
在铺瓷砖的浴室中里，提供一个浴室垫是很常见的：该浴室垫既具有站在上面能防滑的非瓷砖表面；同时又具有一定吸收性能，以便吸收不可避免的来自水槽、浴缸、淋浴喷头中的水。因此，发明人认为有必要提供一种舒适、防滑并且吸收性的浴室垫，其还容易变干。
发明内容
根据本发明的一方面，涉及一种制造带衬垫的吸收性垫的方法，包括按照如下顺序进行的步骤：在尺寸适于用作垫子的一种薄板上提供吸水性的、速干的编织织物(woventextile)材料；将吸水性的、速干的编织织物材料粘合到粘弹性的聚氨酯泡沫材料做成的薄板上，该材料具有开放的蜂窝状构造；将织物材料缝合到泡沫材料上，以获得经缝合过的织物和泡沫组件；然后将经缝合过的的织物以及泡沫组件的泡体材料这一面粘合到防滑的经涂胶的(rubberized)基础材料做成的薄板上。
根据本发明的另一方面，涉及一种缓冲垫，其包含了一种吸水性、速干的编织织物材料层，一种具有开放的蜂窝状构造的粘弹性聚氨酯泡沫材料层，一种粘合且缝合到编织织物材料层以形成织物和泡沫组件的泡沫材料层，一种粘合到织物和泡沫组件中泡沫体材料这一面的经涂胶的基础材料层。
本发明的上述和其它目的、特征、性能，以及操作方法、结构中相关元件的功能、各部分的组合以及生产规模，在参照附图考虑以下说明书和附加权利要求后将更加清楚，而这些实施例、权利要求和附图都是说明书的组成部分。相同或类似的参考编号表示不同附图中的相同部件。然而，必须要清楚地理解，附图仅仅是为了说明和解释，并不能被认为是本发明的限制。在说明书和权利要求书中，单数形式的“一”和“这个”包括了复数形式，除非文中明确指出相反的意思。
附图说明
图1简要示出了根据本发明的一个浴室垫子实施例的、在吸收层的制作中使用的线股(strand)的剖面图；
图2简要示出了根据本发明的一个浴室垫子实施例的、在图1中用于形成吸收层材料的多股线股的剖面图；
图3简要示出了根据本发明的一个实施例的浴室垫的剖面图。
具体实施方式
图1示出了在本发明中使用的类型的纱线2的剖面图，所述纱线形成编织织物材料，所述编织织物材料再形成浴室垫的吸收性层。纱线包括纤维4的一定数目的线股，这些线股是从纤维源(sourcefiber)中分离出来，并且随后与多个额外添加的纤维编织在一起，以形成纱线2。纱线能够使得线股、进而使得材料能够吸收水分5，从而并不是使液体在材料上进溅，而是使得液体被快速吸收，因此将液体从已经被施用了该材料的其它表面移除，并使得在其它表面上起到干燥的作用。在一个实施例中，每根纤维4的直径在几微米精度量级。比如，合适的范围可能在1至20μm，更特殊的使用范围则可能在5至10μm。经过比较，这个范围可认为比人的头发还要细约100倍，典型地，每支纱线是用100根纤维来形成的。因此能够想到，每根线股的横截面区域都特别小，并且随后使用每根线股与其它线股相结合，来形成如图2所示的编织织物材料。在一个实施例中，纤维是具有线密度小于约1丹尼尔/丝的微纤维。
从纱线形成材料的织造过程包括了将纱线和其他多股纱线一起织造形成如图2所示的那种类型的编织织物材料6。
在一个实施例中，编织织物材料包括聚酯和聚酰胺(例如尼龙)的多股线股的组合。特别地，一个实施例中包含了60％至90％质量比的聚酯，余下的则为聚酰胺。
为了形成如图3所示的浴室垫20，将多根纱线2编织在一起形成具有非常优良的吸收能力和干燥特性的编织织物材料6。在一个实施例中，织品被编织成材料，质量在200至300g/m2之间。在一个特别的实施例中，材料的质量在250至275g/m2之间。
在实践中，这种材料的吸收能力极大地优于常规的纯棉毛巾布或聚酯编织物材料。另外，它的变干速度比纯棉毛巾布更快，甚至比100％的聚脂聚酯材料快。在一个实施例中，编织织物材料6的起绒高度约为0.1至0.175英寸，特别地，为约0.157英寸。
编织织物材料6使用胶粘剂而粘合到缓冲层8上，在一个实施例中，要选择既能在聚氨酯与编织物材料之间提供强固的粘接、又具有充足的柔韧性以使垫子弯曲时胶粘剂层不会出现显著地破裂开胶粘剂层。在一个特别的实施例中，胶粘剂必须考虑到湿气从聚氨酯泡沫向编织织物材料转移时，不妨碍编织织物材料的导湿或芯吸(wicking)/干燥功能。在一个特别的实施例中，胶粘剂可以是可喷射的室内饰品喷胶，适合和诸如680S泡沫板一起使用，在中国广东的TaiJia品牌下就有这种泡沫板。
缓冲层8可以由记忆泡沫材料制成，例如具有开放的蜂窝状构造的粘弹性聚氨酯泡沫。一般来说，这种材料具有吸水性但是干得很慢，尤其是和上文提到过的微纤维编织材料相比而言。
作为一个例子，缓冲层8的厚度可能为约2.5cm，且一般来说，可以在1cm到5cm之间。对于更薄的缓冲层，则缓冲功能不足；而对于更厚的缓冲层，整个垫子的厚度就太大了，使用者可能觉得他或她的脚深深陷入了垫子中。在一种典型的垫子中，泡沫的密度大约在2.8lbs/ft3左右。
发明者认为在上述的组合中，编织织物材料6的吸收能力和干燥特性考虑使用相对吸水性较好但干燥较慢的聚氨酯泡沫，即使在通常比较湿润/潮湿的环境中，例如浴室。在这种组合中，吸水性的编织织物材料6能够通过毛细作用从聚氨酯带走在一个面22处聚集的湿气，而在另一面24干得相对快些。
一旦编织物材料6粘合到缓冲层8，两者便缝合在一起形成附加强度，可选地在编织织物材料6的上表面24产生装饰性设计，图中未示出。
经缝合、粘合后的组合垫然后粘合到防滑的经涂胶的基础材料10上。例如，防滑层10可以由聚氨酯材料制成，包括例如聚氨酯-聚脲素基弹性纤维(spandex)。所述组件随后连接到例如由编织织物材料6制成的边框上。
在一个实施例中，垫子的面积可以在4至8平方英尺之间。
虽然本发明在细节上的描述是为了说明目前被认为最实用和最优的实施例，但要明白这些细节仅仅是为了这些目的，且本发明并不局限于公开的实施例。与此相反，它包含了在附加的权利要求的精神和范围之下的变形例和等效例。例如，要明白本发明最大限度地考虑到了任何一个实施例的一个或多个特征可以和任何一个其他实施例的一个或多个特征进行组合。

Claims (2)

1.一种制造缓冲吸收垫的方法，包括按照如下顺序进行的步骤：
在大小适合用作垫子的一种薄板上提供吸水、速干的编织织物材料；
将吸水、速干的编织织物材料粘合到聚氨酯泡沫材料做成的薄板上，该材料具有开放的蜂窝状构造；
将编织织物材料缝合到聚氨酯泡沫材料上，得到缝合过的织物和泡沫组件；然后
将缝合过的织物和泡沫组件的编织织物材料这一面粘合到防滑的经涂胶的基础材料做成的薄板上；
所述编织织物材料，包括聚酯和聚酰胺的多股线股的组合，包含了60％至90％质量比的聚酯，余下的则为聚酰胺；
形成编织织物材料的纱线包括纤维的一定数目的线股，这些线股是从纤维源中分离出来，并且随后与多个额外添加的纤维编织在一起，以形成纱线。
2.一种缓冲吸收垫，包括
一种吸水、速干的编织织物材料层；
一种具有开放的蜂窝状构造的聚氨酯泡沫材料层，该聚氨酯泡沫材料层粘合且缝合到编织织物材料层以形成织物和泡沫组件；
一种粘合到织物和泡沫组件中的编织织物材料这一面的经涂胶的基础材料层；
所述编织织物材料，包括聚酯和聚酰胺的多股线股的组合，包含了60％至90％质量比的聚酯，余下的则为聚酰胺；
形成编织织物材料的纱线包括纤维的一定数目的线股，这些线股是从纤维源中分离出来，并且随后与多个额外添加的纤维编织在一起，以形成纱线。
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