JPS6355941B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method of manufacturing a Kenko mat which has a large number of projections and which exerts an acupressure effect on the human body.

In recent years, instead of a mere cushion body made of soft cushioning materials (such as urethane foam), more and more healthy mats have been used as core bodies, such as foamed polyethylene, which improves the overall strength of the mat. In addition, products are becoming available that have protrusions formed on both the cushion body and the core body to enhance the acupressure effect.

Conventionally, in the production of health mats containing this type of core, the core and two cushion bodies laminated on both sides of the core were separately molded, and then bonded together to integrate them. It was done by. Therefore, not only is a molding process and accompanying molds required depending on the number of core bodies and cushion bodies, but also a specific shape is formed in the core body to be included, so the bonding process is difficult. It had some drawbacks. That is,
In order to obtain an integrated healthy mat in a good bonding state, in other words, in a state of close contact with each other, the cushion body must be formed into an accurate shape corresponding to the shape of the core, and the core and cushion body must be formed in an accurate shape. Regarding this, considerably high dimensional accuracy was required at the bonding site. Furthermore, even if both are molded with high dimensional accuracy, the cushion body is quite soft and difficult to maintain a constant shape, and since mats generally have a large area, both can be molded over the entire area. Accurate positioning was a difficult task. Therefore, there was a problem in that it was difficult to obtain a good bonding condition for both.

The manufacturing method of the present invention does not involve such a pasting process, which has been a problem in the past, but instead involves inserting a core into a mold and performing foam molding to enclose the core. That is, one of the molds has a shape corresponding to the uneven shape of the cushion body, the other side is provided with a protruding holding part, and the opposite side of the protruding surface of the core body is held in the mold by the protruding holding part, Then, the tip of the protrusion of the core body is positioned so as to come into contact with the uneven convex part of the mold, and a foamable material is injected into the mold, and then the foamable material is foamed to form a mold that encloses the core body. This is a manufacturing method for obtaining pine.

In particular, in the manufacturing method of the present invention, when enclosing the core, a protrusion formed on one side of the core is brought into contact with an uneven convex portion of a mold, and the other side of the core is provided in the mold. The feature is that the core body and cushion body are integrally manufactured by holding the core body with a protruding holding part, ensuring the desired enclosing state, and foam-molding it in a mold so that the core body is encapsulated within the core body. It is.

That is, there is no need to provide a special holding member to hold the core in the mold, and the core is held by the shape of the core and the shape of the mold itself. Therefore, according to such a manufacturing method, the uneven shape of the cushion body of the health mat can be imparted by various changes to the mold itself, and the health mat has a more complex shape than the conventional bonding method. It also has the advantage of being easy to manufacture.

Note that the protrusions of the core body and the concave-convex convex portions of the mold should be in contact with each other at sufficient locations to bring the core into the desired enclosing state, and it is not necessary that all the protrusions come into contact with the convex portions. There is no need for contact.

Hereinafter, one embodiment of the present invention will be described based on the drawings.

First, a core 1 as shown in FIG. 1 is molded using a core mold (not shown). A large number of protrusions 2 are formed on one side of the core 1. Note that the core body 1 has a plurality of communication holes 3 that are open on both sides.
However, this communication hole is for ensuring uniform rotation of the foam material, and is not necessarily required to be formed.

Next, as shown in Figure 2, type A for healthy pine
Next, the core body 1 is set in the mold open state. Here, mold A for health mats is upper mold 4.
and a lower mold 5, and the upper mold 4 is rotatable with respect to the lower mold 5 via a connecting member 6, thereby allowing accurate opening and closing operations of both 4 and 5. . The core body 1 is set by pins (protruding from the holding part 4a) 7 through the holding parts 4a provided on the upper mold 4 with respect to the upper mold 4 in the upright state. In the set state, the inner surface of the upper mold 4 and the other surface of the core body 1 (the surface on which the protrusions 2 are not formed) face each other, and the holding portion 4a is present. Since they are spaced apart, a first space 9 is thereby formed on the other surface side of the core body 1. This first space 9 corresponds to the cushion body 8 to be formed on the other side of the core body 1. At the same time, a foamable material a as a cushioning material is injected into the lower mold 5.

Thereafter, by tilting the upper mold 4, the health mat mold A is clamped as shown in FIG. As a result, in addition to the first space 9, a second space 10 is also formed on one side of the core body 1. This second space 10 corresponds to the cushion body 8 to be formed on one side of the core body 1.

The inner shape of the lower mold 5 is the surface shape of a healthy pine tree,
In other words, a large number of reversely directed protrusions 11 are formed to determine the uneven shape, and the reversely directed protrusions 11 are similar to the protrusions 2...
, their positions and numbers are the same (excluding those located at the outermost positions of the opposite protrusions 11...), so that when the mold is clamped, the protrusions 11 and 2 are in contact with each other at the tip of each protrusion. They are in contact with each other. Therefore, on one side of the core body 1, the holding portions 4a are present in the first space as the cushion body 8 forming space, but on the other side, the cushion 8 is formed in the second space 10. There is nothing to prevent it. Furthermore, since the size of the core body 1 in the surface extending direction is slightly smaller than that of the mold A, a gap 12 is formed between the core body 1 and the mold A in the same direction. .

Thereafter, the foamable material a is foamed in the health mat mold A by pressurizing and heating the mold A. Then, the foamable material a moves from the second space 10 located on one side of the core 1 to the first space 9 located on the other side via the communication holes 3 and the gaps 12, Since foaming occurs, the cushion body 8 is formed on both sides of the core body 1 and in the communication holes 3 and the gaps 12, and the integration of the cushion body 8 and the core body 1 is completed.

Thereafter, by raising the upper mold 4, the health mat mold A is opened, and the integrated product consisting of the core body 1 and the cushion body 8 is taken out from the mold A. and,
In this integrated product, a corresponding cushion body 8' is separately inserted into the part where the holding part 4a was present, and a cloth or the like is pasted on the outer periphery of the body if desired, thereby obtaining a health mat as a product. Can be done.

Here, the healthy pine tree obtained in the above example will be described. As shown in FIG. 5, the mat has a convex portion 13 formed on the cushion body 8 (that is, one formed due to the absence of the reverse convex portion 11 of the lower die 5) on the core body 1. They do not exist in the positions corresponding to the formed protrusions 2..., but conversely, the bottom surfaces of the recesses 14 of the cushion body 8 (which are necessarily formed between the protrusions 13)... The protruding ends of the protrusions 2 of the core body 1 abut against each other, and the protruding ends of the protrusions 2 are exposed without passing through the cushion body 8 and are in an open state.

Therefore, when using the health mat obtained by the method of the present invention, the convex portions 13 of the cushion body 8 easily sink into the concave portions of the core body 1 located directly below, so that the side in contact with the body It is easy to form a flat surface in the body, stabilizing the posture, and the convex part of the cushion body is more recessed in the high-load area, so that the protrusions 2 of the core body 1 can apply direct acupressure effectively. It is something that can be demonstrated.

In addition, the material of the core to be included in the health mat according to the method of the present invention is one that is relatively harder than the material of the cushion body in order to exert the acupressure effect, and examples thereof include foamed synthetic resins such as polyethylene and polystyrene. . In addition, examples of the cushion body material that encloses the core include soft foamed synthetic resins, such as urethane foam, which are commonly used as mat materials.

In the embodiment described above, the protrusions 2 of the core body 1 and the reversely directed protrusions 11 of the lower mold 5 are made to substantially match in number and size, but such a limitation is not necessarily required.

For example, as long as the holding function of the core body 1 during molding is preserved, the number of reverse protrusions 11 is made smaller than the number of protrusions 2, and adjacent reverse protrusions 11 are made.
The interval between the formations may be widened. Therefore, the inner shape of the lower mold 5 and the surface shape of the healthy mat can be changed.

In addition, the mold A for health mats, especially the upper mold, is equipped with an air vent hole for removing air existing in the mold A (including both the air existing from the beginning and the air generated by foaming). Good.

As described above, according to the present invention, the core body and the cushion body are integrated using the foaming of the foamable material, and the core body is held on the surface side of the health mat during the molding of the cushion body. Since this is carried out using the mold itself without the presence of a separate holding means, it is possible to obtain a healthy mat with better integration than with conventional bonding methods.

[Brief explanation of drawings]

FIG. 1 is a cross-sectional view of the core, FIGS. 2 and 3 are diagrams for explaining the procedure of an embodiment of the present invention, and FIG. 4 is a diagram of the health mat produced according to the present invention. FIG. 5 is a cross-sectional perspective view of a healthy pine tree. 1...Core body, 2...Protrusion, 3...Communication hole, {4
...upper mold, 5...lower mold} (for healthy mats) type A,
4a...Holding part, 9...First space, 10...Second
Space, a... foamable material.

Claims (1)

[Scope of Claims] 1. A method for manufacturing a health mat, which includes a core body having a large number of protrusions formed on one surface, and has an uneven shape on a cushion body located on the protrusion surface side of the core body, comprising the steps of: One side has a shape corresponding to the uneven shape of the cushion body, the other side is provided with a protruding holding part, and the opposite side of the protruding surface of the core body is held in the mold by the protruding holding part, and the tip of the protrusion of the core body is 1. A method for producing a healthy mat, which comprises: placing a foam material in contact with a concave-convex convex portion of the mold, injecting a foamable material into the mold, and then foaming the foamable material.