KR101395676B1 - Air cushion mat manufacturing method and air cushion mat thereof - Google Patents

Abstract

The present invention relates to a manufacturing method for an air cushion mat and an air cushion mat manufactured thereby. The manufacturing method manufactures an air cushion mat (10) comprising: a cushion part (11) equipped with multiple air pockets (11a) and a communication path (13); a lower plate part (12) of a flat plate structure which covers the bottom side of the cushion part (11); and an air injection hole (14) arranged in order to inject outside air at one side of the cushion part (11). The manufacturing method for an air cushion mat comprises: a blower molding method of manufacturing an air cushion mat by injecting high pressure air into a tube made up of thermosetting rubber within a mold with a blower device; and a manufacturing method of bonding the cushion part (11) and lower plate part (12) through an ultrasonic attachment process by separating and manufacturing the cushion part (11) and lower plate part (12) by injection molding. The present invention forms an assistant air injection part (16) on one side of the air pocket (11a) of the cushion part (11) and bonds a bellows injection tube (17) equipped with a check valve (19) for air injection and the assistant air injection part, thereby providing the air cushion mat capable of conveniently and additionally performing air injection according to the needs of a user.

Description

TECHNICAL FIELD [0001] The present invention relates to an air cushion mat manufacturing method and an air cushion mat,

The present invention relates to a method of manufacturing an air cushion mat and an air cushion mat according to the manufacturing method. More particularly, the present invention relates to a method of manufacturing an air cushion mat using a cushion part and a lower plate part by blow molding in a mold using a tube shape of synthetic rubber such as urethane rubber. It is an object of the present invention to provide an air cushion mat which is capable of producing an air cushion mat without any separate bonding process, The present invention relates to a method of manufacturing an air cushion mat capable of improving the productivity through simplification and greatly reducing the manufacturing cost, and an air cushion mat by the manufacturing method.

Generally, the air mat is widely used because it is easy to carry and has less adherence to the installation place as a tool for injecting air and resting on the air cushion through an air pressure formed therein.

The air mat is composed of a cushion portion having a plurality of air bag shapes and a lower plate portion bonded to the lower surface of the cushion portion.

An air injection hole for injecting air into each air bag is formed at one side of the cushion portion and the lower plate portion.

Each of the air bags is configured to communicate with each other through a communication passage so that the air injected through the air injection holes is supplied to each air bag through the communication passage.

Prior art relating to such air mats is disclosed in Korean Utility Model Registration No. 0175359 (published on March 15, 2000), Registered Utility Model No. 0250619 (published on October 19, 2001), Registered Utility Model No. 0286835 (Published on Aug. 24, 2002), Published Patent Publication No. 2008-97961 (published on November 6, 2008)

Such conventional air mats have generally been manufactured through slush molding, and the process is as follows.

First, when the inside of the mold is filled with a plastic resin and then a portion of the resin is coated to a necessary thickness on the inner surface of the mold after preheating, the resin layer coated with a certain thickness is completely gelled and cooled, The cushion part is first made.

And then a step of forming a communication passage for communicating the air bags of the cushion portion with each other is performed and a joining step for bonding the previously prepared lower plate portion to the cushion portion is completed.

However, in the conventional air mats manufacturing method using such a slush molding, since molding is performed in a state where the upper part of the mold is opened due to the characteristics of the slush molding, when the cushion part is formed, the lower plate part can be joined to the cushion part have.

Therefore, although the process of joining the cushion part and the lower plate part must be separately performed, the air mat is finally completed. Particularly, the bonding process between the cushion part and the lower plate part is usually performed by high-frequency bonding or bonding bonding. Since the high-frequency bonding requires a separate high-frequency bonding device and the bonding process takes a long time, Which results in a problem that the unit price of the product increases.

Particularly, bonding bonding requires a long process time like high frequency bonding, and most of the bonding bonding is manually performed, so that it is difficult to firmly bond the cushion part and the lower plate part. In addition, a communication passage must be formed between the air bag and the air bag of the cushion part so that air can smoothly enter each air bag. Since the slush molding is inevitably molded in only a simple shape, the communication passage of the cushion part is formed by molding It is necessary to form it through a separate communication channel forming process.

Therefore, there is a problem that the whole process is delayed and the unit price of the product is increased.

In addition, due to the characteristics of the slush molding, when the plastisol is pulled out, the residues remain unevenly on the surfaces of the air bags remaining in the mold, and the thickness of the air bags can not be uniformly formed by these residues, Accidents occurred frequently.

In order to solve the problem of the manufacturing method through such slush molding, there is proposed a method of manufacturing a slush molding by using a slush molding method, such as a method disclosed in Korean Patent Publication No. 0768551 (published on Oct. 18, 2007), Registered Patent Publication No. 1145330 (published on May 15, 2012) 1191350 (October 20, 2012 announcement) have been developed and disclosed.

1, the resin composition 3 is first injected into the mold 5, and the lower mold 3 is poured into the lower mold 4. In this case, The resin composition 3 in the mold 5 is rotated by the centrifugal force in the rotating process by rotating the mold 5 and the lid 6 in a predetermined trajectory after the lid 2 and the lid 6 are coupled, So that the cushion part 1 is formed and moved to the lower plate part 2 so that the cushion part 1 and the lower plate part 2 are naturally bonded to each other.

The resin composition (3) constituting the cushion part (1) and the lower plate part (2) of the air mat of the conventional structure constructed as described above is a basic synthetic resin such as polyvinyl chloride, synthetic rubber and polyurethane, A plasticizer is mixed in a large amount in order to increase the thermoplasticity of the synthetic resin so as to smoothly perform molding at a high temperature and to allow the cushion portion 1 to have sufficient elasticity and flexibility.

Phthalates such as DINP (Diisonony 1 phthalate), DNOP (di-n-octyl phthalate) and DIPI (Diisodecyl phthalate) are mainly used as the plasticizer.

At this time, the plasticizer is injected with about 80 to 120 Phr so that the cushion part 1 can be smoothly formed at a high temperature and has sufficient elasticity and flexibility after molding. Phr stands for "per hundred resins or parts per hundreds of rubber" and is the additive weight (eg, kg) added per "100 weight of polymer (eg, kg)". That is, when 1 kg of the additive is mixed with 100 kg of the polymer, it becomes 1 phr.

However, when a large amount of expensive plasticizer is added as described above, the manufacturing cost increases. In order to sufficiently maintain the rigidity of the lower plate portion 2 made of the same material as the cushion portion 1 due to the characteristics of the rotation molding method, The amount of the resin composition 3 to be added is increased to increase the manufacturing cost.

Further, even when the cushion part 1 and the lower plate part 2 are separately formed and joined, the same material is used to increase the coupling force between the cushion part 1 and the lower plate part 2, There is a problem.

Since such a rotation molding method requires a separate communication member (not shown) in the mold 5 during the molding process, unnecessary waste of the material occurs, the manufacturing process is increased, and the rotation molding process is performed manually. There is a problem in that it is difficult to mass-produce.

In the case where a communication member is not used to improve the problem, the thickness of the coating to be coated is varied due to the temperature difference transmitted to the cutting groove forming portion and the air bag forming groove forming portion during the rotation molding operation, .

1. Registered Utility Model No. 0175359 (Registered on April 15, 2000, name: Air Matt of Bed) 2. Registered Utility Model No. 0250619 of the Republic of Korea (published on October 19, 2001, name: air distribution mat) 3. Registered Utility Model No. 0286835 (Registered on April 24, 2002, Name: Air Mat) 4. Korean Patent Laid-Open Publication No. 2008-97961 (published on November 6, 2008, entitled: 5. Korean Registered Patent Publication No. 0768551 (published on October 18, 2007, entitled: Air Mat, Manufacturing Method and Molding Apparatus) 6. Korean Registered Patent No. 1145330 (issued May 15, 2012, entitled: Air Mat, Air Mat Production Apparatus and Manufacturing Method) 7. Korean Patent Registration No. 1191350 (published on Oct. 18, 2012, entitled: Combined Air Matt and Manufacturing Method Thereof)

As described above, according to the present invention, it is possible to manufacture an air cushion mat by using a resin composition in powder form when manufacturing an air mat according to the prior art, and applying a new method different from that used in the slush molding method or the rotation molding method And to provide a method.

That is, an object of the present invention is to provide a cushion and a lower plate, which are formed by using a tube shape made of a synthetic rubber such as urethane rubber without using a resin composition in powder form, Air cushion mat according to the present invention makes it possible to improve the productivity by greatly simplifying the process and to greatly reduce the manufacturing cost as compared with the conventional slush molding method and rotation molding method, Air cushion mat.

Another object of the present invention is to provide a cushion part and a lower plate part by an injection molding method and then joining the lower plate part and the cushion part by ultrasonic bonding so that the cushion part can be easily manufactured by injection molding even if it has a complicated shape, The present invention provides a method of manufacturing an air cushion mat and a method of manufacturing the air cushion mat by which the productivity is improved and the manufacturing cost is greatly reduced by relatively simplifying the process as compared with the molding method and the rotation molding method.

Particularly, another object of the present invention is to provide a cushion part of a pneumatic cushion mat, wherein the cushion part is designed to have a uniform thickness by means of a blow molding method through a mold which has not been applied to the conventional air cushion mat production, and injection molding and ultrasonic bonding, So that it is possible to greatly improve the durability of the air cushion mat, and to provide an air cushion mat by the manufacturing method.

According to an aspect of the present invention, there is provided a cushioning device comprising: a cushion part having a plurality of air bags and a communication path; a lower plate part having a flat plate structure for covering the bottom surface of the cushion part; A method of manufacturing an air cushion mat including an air inlet, comprising the steps of: forming a cushion part mold having a cushion molding part provided to form the cushion part; and a lower plate part mold coupled to the cushion part mold to form a lower plate part A step of inserting an air injection tube connected to a blowing device into a tube made of thermoplastic rubber and heating the tube at a high temperature to supply the tube into a mold; Thereby forming a contact portion between the flat portion of the lower mold half and the flat portion of the cushion molded portion, And in this state, high-pressure air is injected from the blower device to form an air cushion mat, in which one side of the tube bulges along the cushion-forming portion to form a cushion portion and the other side surface of the tube is formed as a lower plate portion And an air cushion mat having a cushion portion, a lower plate portion, and an air inlet in the mold is cooled in a state where the air cushion mat is completed, and a gap between the lower plate portion mold and the cushion portion metal is increased, And separating the air cushion mat from the air cushion mat.

Here, the air cushion mat is manufactured in a state in which the auxiliary air injection unit is formed in the air bag position of one of the portions formed by the air bag of the cushion unit in the cushion forming unit, It is preferable that a bellows injection pipe having a check valve for injecting air is seated on the auxiliary air injection unit.

The cushion forming part has a plurality of recessed structures recessed in a structure opposed to the cushion part so as to form a communication path with a plurality of air bags. The four side edge surfaces of the cushion forming part forming the air bag are cut It is preferable that the cutting portion tube is cut into the entire size of the cushion-formed portion in the process of pressing the tube with the lower plate mold and the cushion portion mold and thermally fusing the tube.

According to another aspect of the present invention, there is provided a cushioning device comprising: a cushion portion having a plurality of air bags and a communication path; a lower plate portion having a flat plate-like structure for covering the bottom surface of the cushion portion; A manufacturing method for manufacturing an air cushion mat including an injection port, comprising the steps of: preparing an injection mold designed according to the shape of the cushion portion and the shape of the lower plate portion; injecting a molten material melted by heating the thermoplastic rubber into each of the injection molds The cushion part and the lower plate part being injection-molded separately from each other, and bonding the injection-molded cushion part and the lower plate part by ultrasonic vibration in an ultrasonic bonding machine, A vibration cathode facing the joint surface of the cushion portion is provided at one side and a vibration cathode opposite to the shape of the lower plate portion is provided at the other side A cushion portion to be joined on the lower plate portion is tightly fixed, and a vibration cathode is disposed in close contact with the cushion portion along a portion where bonding of the cushion portion and the lower plate portion is required And the cushion part and the lower plate part are joined together by applying an appropriate pressure in this state and at the same time applying ultrasonic vibration transmitted to the vibrating cathode through the oscillator to the part where bonding is required .

At this time, in the process of injection molding the cushion part in the injection mold, the auxiliary air injection part is formed at one air bag position of the part formed by the air bag of the cushion part. And a bellows injection pipe having a check valve for air injection is seated on the subsidiary auxiliary air injection unit.

That is, according to the present invention, the cushion part and the lower plate part are integrally manufactured by blow molding in the mold, or the cushion part and the lower plate part are separately manufactured through injection molding in the injection mold, And an air cushion mat for integrally manufacturing a lower plate portion and a lower plate portion.

According to the present invention, the air inlet port of the air cushion mat is provided with an injection port formed to be capable of injecting outside air, a check ball supported by a spring member disposed on the injection path communicated with the injection port, It is preferable that a check valve having an O-ring disposed on the interface between the injection port and the injection flow passage is inserted and mounted.

An air circulation pipe connection port is provided at one side of the air cushion mat separately from the air inlet port of the air cushion mat. An air circulation pipe is connected to the connection port of the air circulation pipe. A pressure gauge, a solenoid valve, A circulation control box equipped with a pump, a temperature sensor, a microcomputer, and an electric heater. In addition, as the air circulation pipe is circulatively connected to the air inlet, the heated air circulates through the heating device to perform a heating function have.

According to the present invention, an air circulation pipe connection port is provided at one side of the air cushion mat separately from the air inlet port of the air cushion mat. An air circulation pipe is connected to the connection port of the air circulation pipe, A circulation control box equipped with a solenoid valve, a circulation pump, a temperature sensor, a microcomputer, and a cooling device are installed. In addition, as the air circulation pipe is circulatingly connected to the air inlet, the air cooled by the cooling device circulates to perform a cooling function It is possible.

According to the present invention, there is provided a manufacturing method capable of manufacturing an air cushion mat without separately joining the cushion part and the lower plate part through a blow molding method in a mold by using a tube form made of synthetic rubber such as urethane rubber, There is an effect that the productivity can be improved and the manufacturing cost can be greatly reduced by relatively simplifying the process without using the resin composition in powder form as in the conventional slush molding method or the rotation molding method.

Further, according to another embodiment of the present invention, the cushion part and the lower plate part are respectively manufactured through the injection molding method, and then the lower plate part and the cushion part are joined by ultrasonic bonding, so that even if the cushion part has a complicated shape, Therefore, compared with the conventional slush molding method and the rotation molding method, the productivity can be improved by simplifying the process and the manufacturing cost can be greatly reduced.

As described above, according to each embodiment of the present invention, the cushion portion of the air cushion mat is formed by the blow molding method through the mold, which is not applied to the conventional air cushion mat production, and the injection molding and the ultrasonic bonding, It is possible to greatly improve the durability of the air cushion mat.

Particularly, according to the present invention, the bellows injection tube, which is an auxiliary air injection means, is integrally mounted to the air bag of the cushion part through the auxiliary air injection part in the air cushion mat manufactured by the above- When the air injection is additionally required, the external air can be easily injected into the cushion part through the operation of pressing the bellows injection tube.

In addition, according to the present invention, a circulation control box equipped with a pressure gauge, a solenoid valve, a circulation pump, a temperature sensor, a microcomputer, a heating device including an electric heater, and a cooling device are required to circulate cooling / The air cushion mat can be provided with a cooling and heating function on an air cushion mat which can be variously modified by a cushion cushion, a bedsore prevention mat, a chair mat, a bed mat, and the like.

1 is a view showing a process of manufacturing an air mat by a rotation molding method according to a conventional technique.
2 is an exploded perspective view schematically showing a mold for manufacturing an air cushioning mat according to the present invention.
FIG. 3 is a perspective view showing a combined state of a lower plate part mold and a cushion part mold for manufacturing the air cushion mat according to the present invention. FIG.
4 to 8 are sequential process drawings showing a process of manufacturing an air cushion mat in a mold by a blower molding method according to the present invention in a schematic sectional structure.
9 is a view exemplarily showing a state in which a cushion portion is manufactured by injection molding and then a lower plate portion is joined to the cushion portion by ultrasonic bonding as another embodiment of the present invention.
10 is a perspective view showing an air cushion mat manufactured by a blow molding method according to the present invention.
11 is a sectional view of FIG. 9 showing the configuration of an air cushion mat manufactured by a blow molding method according to the present invention.
12 is a use example showing a state in which a heating function is given to an air cushion mat according to the present invention.
13 is a use example showing a state in which a cooling function is given to an air cushion mat according to the present invention.
FIG. 14 is a use example showing a state in which a plurality of air cushion mats are connected in series to utilize the air cushion mat according to the present invention as a mat for a bed. FIG.

Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings.

In order to explain the preferred embodiments of the present invention, the thicknesses of the lines and the sizes of the components shown in the attached drawings may be exaggerated or omitted for clarity and convenience of description, Terms to be given are terms defined in consideration of the functions of the present invention, which may vary depending on the intention or custom of the user, the operator.

9 to 11, the air cushion mat 10 according to the present invention is characterized in that a plurality of air bags 11a are aligned and disposed adjacent to each other, and the adjacent air bags 11a are connected to the communication path The lower plate portion 12 of the flat plate structure integrally blocks the opening portion of the air bag 11a of the cushion portion 11 by a cushion portion 11 having a structure capable of air circulation And a mat (or cushion) having a cushioning function.

An air inlet 14 communicating with the outside is formed at one end of the air bag 11a of the cushion part 11. [

Here, the cushion part 11 is preferably made of urethane rubber or thermoplastic rubber (TPR), which is a kind of synthetic rubber, so as to have elasticity and flexibility, but is not limited thereto, It is of course possible to use a wide variety of synthetic rubber materials.

The lower plate 12 is formed in the shape of a flat plate so as to support the air bag 11a of the cushion part 11 to form a cushion space and is made of the same material as the cushion part 11 .

Meanwhile, in order to manufacture the air cushion mat 10 having the shape shown in the attached drawings, the slush molding method or the rotation molding method has been used as described above. However, in the case of the present invention, And a method of manufacturing the air cushion mat 10 by an injection molding method.

That is, although a blow molding method (blow molding method) in which a hollow container is formed by injecting air into a flatly pressed molding tube by a blower is already known, In the production of the air cushion mat 10, a method of manufacturing by using the blower of the conventional hollow molding method has not been studied and disclosed.

The applicant of the present invention has been made aware of the fact that, when the air cushion mat 10 is manufactured, the hollow molding method using the conventional blower can uniformly form the thickness of the hollow container when the hollow container is molded, As a method of uniformly forming the entire thickness of the cushion part 11 while integrally manufacturing the cushion part 11 and the lower plate part 12 constituting the cushion part 10 without any separate joining step, It was invented.

In order to manufacture the air cushion mat 10 according to the present invention, as shown in FIGS. 2 and 3, a mold 20 matching the shape of the air cushion mat 10 should first be prepared.

That is, the air cushion mat 10 of the present invention includes a cushion part 11 having a plurality of air bags 11a and a communication path 13 interconnecting the air pockets 11a in four directions, Since the lower plate portion 12 forming the bottom surface of the flat plate structure integrally formed with the cushion portion 11 and the air inlet 14 capable of injecting air into the air bag 11a of the cushion portion 11, It is a matter of course that a mold 20 is required which conforms to the shape structure of the lower plate portion 11, the lower plate portion 12, the communication passage 13 and the air inlet 14.

2, the mold 20 according to the present invention includes a cushion part mold 22 having a cushion forming part 23 provided to form the cushion part 11, And a lower plate metal mold 21 which is combined with the upper plate 22 to form the lower plate 12.

At this time, the cushion forming part 23 has a plurality of recessed structures recessed in a structure opposed to the cushion part 11 so as to form a plurality of air bags 11a and a communication path 13, The four sides of the cushion forming part 23 forming the air bladder 11a are formed by the cutting part 25 so that the cutting part 25 is formed by cushioning the tube 15, So as to cut the entire size of the forming part 23.

The lower plate metal mold 21 has a flat surface so that the lower plate 12 can be formed while having a structure in which it faces the cushioning mold 22 in an opposed manner.

In particular, on the lower plate metal mold 21, an air injection configuration part 24a is formed to protrude so as to form a half of the air injection port 14, and a cushion part metal mold 22 are also provided with an air injection constituent portion 24b capable of forming the other half of the air inlet 14.

In order to assemble the lower plate part mold 21 and the cushion part metal mold 22 together and to couple them together as one mold 20, a mold assembly stand (not shown) is mounted on the lower plate part mold 21 and the cushion part metal mold 22, 26a and a mold assembly 26b are formed.

The gap between the lower plate metal mold 21 and the cushion metal mold 22 can be adjusted by inserting the mold assembly 26a into the mold assembly hole 26b and guiding the metal mold assembly 26a to be slidable relative to each other.

Here, the cushion forming part 23 is not limited to the shape shown in the attached drawings, but may be variously modified in accordance with the shape of the air bag 11a of the cushion part 11.

The air cushion mat 10 is manufactured by injecting high-pressure air by the blower 30 into the tube 15 in the mold 20 constructed as described above.

Hereinafter, a method for manufacturing the air cushion mat according to the present invention will be described in brief.

In order to manufacture the air cushion mat 10 according to the present invention as shown in FIG. 10, first, a mold 20 (see FIG. 3) including the lower mold half 21 and the cushion half mold 22 shown in FIGS. ).

Then, a tube 15 made of synthetic rubber such as urethane rubber or thermoplastic rubber to be made of the air cushion mat 10 is prepared so as to be supplied into the mold 20.

At this time, the tube 15 is heated to a high temperature and is prepared so that the contact surfaces can be thermally fused when pressed in the mold 20. For example, the heating temperature of the tube 15 may vary depending on the characteristics of the synthetic rubber, but it is preferable that the tube 15 can be heated to a temperature of 160 ° C to 200 ° C to be thermally fused.

The tube 15 prepared by heating at such a high temperature is supplied and inserted into the mold 20 between the lower plate mold 21 and the cushioning die 22 as shown in FIG.

At this time, the air injection pipe 31 connected to the blower device 30 can be formed in the tube 15, and the air injection pipe 31 is inserted into the mold 20. 5 and 6, the air injection pipe 31 inserted into the tube 15 is connected to the air injection constituent portions 24a and 24b of the lower mold part 21 and the cushion part metal mold 22, As shown in Fig.

6, the lower plate metal mold 21 and the cushion metal mold 22 are brought into close contact with each other, and the tube 15 is cushioned with the cushion metal mold 22. In this way, The portions where the flat portion of the cushion forming portion 23 and the flat portion of the lower plate metal mold 21 come into contact with each other are bonded to each other in a heat fusion state, The cushion forming part 15 is seated in the mold 20 in a state of being cut to the size of the cushion forming part 23 by the cutting part 25 formed on the four side edge surfaces of the cushion forming part 23.

When high pressure air is injected into the tube 15 by the blower 30 connected to the air injection pipe 31 in this state, one side of the tube 15 is pressed against the tube 15, The cushion part 11 is formed by the plurality of air bags 11a and the communication path 13 connecting the adjacent air bags 11a in four directions, And the other side surface of the tube 15 which is in contact with the mold 21 is formed by the lower plate portion 12.

Of course, at this time, the contact surfaces of the cushion part 11 and the lower plate part 12 are joined and connected to each other in the form of heat fusion. In the air injection constituent parts 24a and 24b in which the air injection pipe 31 is seated, (14) is formed.

When the air cushion mat 10 having the cushion portion 11, the lower plate portion 12 and the air inlet 14 in the mold 20 is completed in this manner, 21 and the cushion part metal mold 22 so as to separate the air cushion mat 10 from each other. Of course, it is a matter of course that the tube 15 heated at high temperature during the manufacturing process is cooled through the cooling process so that the air cushion mat 10 is finally completed.

10 and 11, the air cushion mat 10 manufactured by the blow molding method in the mold 20 has the cushion part 11 formed with a plurality of air pockets 11a, And a communication passage 13 for communicating the respective air bags 11a. An air inlet 14 communicating with the outside is formed at one end of the air bag 11a.

Particularly, as a preferred embodiment of the present invention, the air cushion mat 10 shown in FIG. 10 has a square structure and can be utilized as a cushion cushion.

According to another embodiment of the present invention, after the cushion part 11 and the lower plate part 12 of the air cushion mat 10 are respectively formed by injection molding, the cushion part 11 and the lower plate 12, It is also possible to manufacture the semiconductor light emitting device 10 by bonding the light emitting layer 12.

That is, in manufacturing the conventional air cushion mat 10, the cushion portion 11 and the lower plate portion 12 were not manufactured by injection molding. This is because the high frequency bonding is difficult when the shape of the cushion part 11 is complicated and the simple bonding by the bonding bonding has a disadvantage that the bonding part is easily deteriorated. Therefore, as described in the prior art, Air mats were manufactured using the method.

The applicant of the present invention has proposed a method of manufacturing the cushion part 11 and the lower plate part 12 in a state where there is no separate joining step in the manufacturing process of the cushion part 11 and the lower plate part 12 by using the blow molding method, A method of separating the cushion part 11 and the lower plate part 12 by injection molding and bonding them through an ultrasonic bonding process by another manufacturing method.

9 shows a state in which the cushion portion 11 and the lower plate portion 12 of the air cushion mat 10 are separately manufactured as another embodiment of the present invention.

Here, although not shown in the accompanying drawings, the cushion portion 11 and the lower plate portion 12 of the air cushion mat 10 are manufactured by injection molding in an injection mold.

As is well known, injection molding is a processing method in which a molten material melted by heating is injected into a mold to solidify or harden (cure) the molded material, and the molding material supplied from the hopper is mixed in a heating cylinder, The material is uniformly plasticized in the process. When a certain amount of material is accumulated at the tip of the screw, the screw is stopped and the molten material is melted in the mold closed by the mold clamping device The material is injected at a high pressure by an injection cylinder and is conventionally used mainly in a molding method of a plastic resin.

However, the applicant has searched for a method of manufacturing the air cushion mat 10 by the injection molding method, taking into account that the synthetic rubber having thermoplastic properties other than the plastic resin can be sufficiently produced through injection molding.

Particularly, when the shape of the cushion part 11 is complicated (that is, the bonding surface is narrow and wide spread) as described above, it is difficult to perform the bonding of the cushion part 11 and the lower plate part 12 by high frequency bonding, In the case of bonding, there is a disadvantage that not only the productivity is lowered but also the bonding bonding site is easily deteriorated and durability is lowered. Therefore, in order to overcome this problem, a method of applying a bonding method by ultrasonic bonding has been searched.

That is, in the case of the present invention, since a thermoplastic material such as urethane rubber or thermoplastic rubber is used, the molten material, which is melted by heating the thermoplastic rubber, is injected into the injection mold and solidified by cooling to form the cushion portion 11 And the lower plate portion 12, respectively, so that the thickness of the cushion portion 11 can be maintained at a uniform thickness and at the same time mass production is possible.

Of course, although not shown, it is natural that the injection mold for the injection molding is prepared according to the shape of the cushion portion 11 and the shape of the lower plate portion 12, respectively.

The cushion portion 11 and the lower plate portion 12 of the air cushion mat 10 manufactured in the injection mold not shown in this figure are shown in Fig.

Ultrasonic bonding is mainly used for joining metals by applying appropriate pressure and ultrasonic vibration when joining two metal materials.

However, it has been confirmed that ultrasonic bonding is possible even when two synthetic rubbers are bonded. Therefore, the cushion part 11 and the lower plate part 12 of the air cushion mat 10, which are difficult to bond by high frequency bonding, And the like.

That is, the cushion part 11 and the lower plate part 12, which are separately manufactured in an ultrasonic bonding device not shown, are joined by ultrasonic vibration. In the ultrasonic bonding device, A negative pressure plate (not shown) having a shape opposite to the shape of the lower plate 12 is provided on the other side and a lower plate 12 is seated on the pressure plate (not shown) A cushion portion 11 to be bonded onto the lower plate portion 12 is tightly fixed to the cushion portion 11 and a vibration cathode (not shown) is formed along a portion where the cushion portion 11 and the lower plate portion 12 are to be joined. In this state, the ultrasonic vibration applied to the vibration cathode (not shown) through the oscillator (not shown) is applied to the portion where the appropriate pressure is applied and the bonding is required, so that the cushion portion 11 And the lower plate portion 12 are bonded to each other.

According to the present invention, a blower molding method in which air is injected into the blowing device 30 in the mold 20 as described above, or a blow molding method in which the cushion part 11 and the lower plate part 12 are separated from each other by injection molding The air cushion mat 10 manufactured by integrally joining the cushion portion 11 and the lower plate portion 12 by ultrasonic bonding is finally formed into a shape shown in Figs. 10 and 11. Fig.

However, the air cushion mat 10 manufactured as described above is maintained at a proper pressure state by injecting air through the air inlet 14 during use.

At this time, it is preferable that a check valve 18 for controlling the air injection state is inserted into the air inlet 14.

The check valve 18 is opened when the outside air is injected into the air cushion mat 10 through the air inlet 14 and the air inside the air cushion mat 10 14).

11, the check valve 18 is formed with an inlet 18a in the outward direction with one end thereof inserted into the air inlet 14, and the inlet 18a communicated with the inlet 18a, And a check ball 18b supported by a spring member 18c disposed on the check valve 18e.

The check ball 18b has a size capable of blocking the entire diameter of the injection port 18a and a diameter smaller than the diameter of the injection path 18e communicated with the injection port 18a.

At this time, it is preferable that an O-ring 18d which is in contact with the check ball 18b is mediated on the interface between the injection port 18a and the injection path 18e. The O-ring 81d serves to increase the adhesion when the check ball 18b closes the injection port 18a.

Therefore, in the case of the check valve 18 having the above-described structure, when the outside air is injected into the injection port 18a, the check ball 18b is pushed backward by the air injection pressure and the spring member 18c is compressed The air introduced into the injection port 18a flows into the air bladder 11a of the cushion part 11 through the injection flow path 18e.

When the inflow of air into the injection port 18a is stopped, the compressed spring member 18c is restored and the check ball 18b is pushed toward the injection port 18a by the air pressure in the cushion part 11, 18b and 18d so as to prevent the air from escaping to the outside.

On the other hand, when the air cushion mat 10 is used for a long time, the inflated air naturally flows out gradually, and the proper cushioning function can not be maintained.

In this case, air should be additionally supplied through the check valve 18 of the air inlet 14. In order to inject air into the check valve 18 of the air inlet 14, a separate air pump (not shown) ) Or a method of direct blowing by a person is used.

However, it is very troublesome to provide a separate air pump, and it is also inconvenient to separately manage and maintain the air cushion mat 10 and the separated air pump.

In the present invention, when air is additionally required to the air cushion mat (10) as described above, an auxiliary air injection means for easily injecting air can be structurally integrated into the air cushion mat (10) Respectively.

9 to 11, when the air cushion mat 10 is manufactured, auxiliary air is injected onto one of the air bladders 11a of the cushion part 11, And a bellows injection pipe 17 is mounted on the auxiliary air injection unit 16. The bellows injection pipe 17 is provided in the auxiliary air injection unit 16,

The bellows injection pipe 17 is firmly joined and fixed to the auxiliary air injection unit 16 by bonding bonding or the like in a state where the bellows injection pipe 17 is inserted into the auxiliary air injection unit 16 in a state in which the air injection is possible.

At this time, check valves 19 are provided on both sides of the bellows injection pipe 17 to control the air injection state according to the air injection direction.

Each of the check valves 19 provided on both sides of the bellows injection pipe 17 has a function similar to that of the check valve 18 inserted into the air inlet 14, 11, it is opened so as to prevent the air inside the cushion part 11 from escaping to the outside.

Therefore, the bellows injection pipe 17 as the auxiliary air injection means is integrally mounted to the air bladder 11a of the cushion portion 11 through the auxiliary air injection portion 16, The external air can be easily injected into the cushion part 11 through the operation of pressing the bellows injection pipe 18 when the air injection is additionally required.

The air cushion mat 10 according to the present invention can be variously modified as a cushion cushion, a bed sores prevention mat, a chair mat, a bed mat, and the like, in particular, as an air mat capable of cooling and heating.

12, an air circulation pipe connector (not shown) is provided at one side of the cushion part 11 separately from the air inlet 14 of the air cushion mat 10, An air circulation pipe 43 is connected to the pipe connection port and a circulation control box 40 and a heating device 41 are mounted on the air circulation pipe 43 and the air circulation pipe 43 is connected to the air inlet 14 The air heated by the heating device 41 is circulated to perform the heating function.

The air circulation pipe 43 is provided with a pressure gauge, a solenoid valve, a circulation pump, a temperature sensor, a microcomputer, etc., The solenoid valve can control the opening / closing of the air circulation pipe 43 according to the circulation of the air. In the temperature sensor, the circulating air The temperature can also be measured and used as a control variable.

At this time, it is preferable that the solenoid valve uses a three-way control valve.

The heating device 41 is an electric heater that heats the air flowing along the air circulation pipe 43 and flows into the air cushion mat 10 so that the air cushion mat 10 performs a heating function .

13 shows a state in which a cooling apparatus is connected to the air cushion mat of the present invention to have a cooling function.

That is, instead of the heating device shown in FIG. 12, the cooling device 42 can be mounted on the air circulation pipe 43 as shown in FIG. 13 to perform the cooling function.

Of course, it is a matter of course that the circulation control box 40 necessary for the cooling circulation is provided on the air circulation pipe 43, and the circulation control box 40 in the cooling circulation is provided with a pressure gauge, A valve, a circulation pump, a temperature sensor, and a microcomputer.

9 to 11, when the air cushion mat 10 is used alone, it can be used as a cushion cushion or a mat for a chair. However, when the air cushion mat 10 is used as a bed mat or the like, The mat 10 is used in connection with each other. That is, as shown in FIG. 14, the air circulation pipes 43 are arranged in parallel in the horizontal and vertical directions according to the size of the bed mat, and then the air circulation pipe 43 is sequentially Series connection structure.

As described above, the technical idea of the air cushion mat 10 according to the present invention has been described with reference to the accompanying drawings, which illustrate the best preferred embodiments of the present invention, but do not limit the present invention.

Further, it is obvious that various modifications and variations can be made without departing from the scope of the technical idea of the present invention by anyone having ordinary skill in the art.

In particular, it should be understood that the air cushioning mat 10 according to the present invention is not limited to the particular form set forth in the foregoing description, but rather should be construed broadly within the spirit and scope of the invention as defined by the appended claims, But should be understood to include all modifications, equivalents, and alternatives falling within the scope of the appended claims.

10: air cushion mat 11: cushion part
11a: air bag 12: lower plate part
13: communication passage 14: air inlet
15: tube 16: auxiliary air injection part
17: Bellows injection pipe 18, 19: Air injection check valve
20: mold 21: lower plate mold
22: cushion part mold 23: cushion molding part
24a, 24b: air injection configuration part 25: cutting part
26a: mold assembly stand 26b: mold assembly operator
30: blower unit 31: air inlet tube
40: circulation control box 41: heating device
42: air conditioner 43: air circulation pipe

Claims (9)

A cushion portion 11 having a plurality of air bladders 11a and a communication passage 13, a lower plate portion 12 having a flat plate structure for covering the bottom surface of the cushion portion 11, A manufacturing method for manufacturing an air cushion mat (10) including an air inlet (14) provided for injecting outside air,
A cushion part metal mold 22 provided with a cushion forming part 23 provided to form the cushion part 11 and a lower plate part mold 22 provided to form the lower plate part 12 in combination with the cushion part metal mold 22, Preparing a mold (20) composed of a metal mold (21)
A step of inserting an air injection tube 31 connected to the blowing device 30 into a tube 15 made of thermoplastic rubber and heating the tube 15 to a high temperature and feeding the tube 15 into the mold 20,
The tube 15 inserted in the mold 20 is compressed by the lower mold part 21 and the cushion part mold 22 so that the flat part of the lower mold part 21 and the flat part of the cushion forming part 23 In this state, high pressure air is injected from the blower device 30 so that one side of the tube 15 bulges along the cushion forming part 23, Forming an air cushion mat (10) formed of a lower plate portion (11) and the other side surface of the tube (15) being formed of a lower plate portion (12)
The air cushion mat 10 having the cushion portion 11, the lower plate portion 12 and the air inlet 14 in the mold 20 is cooled in a completed state and cooled down, 21) and the cushion part metal mold (22) so as to separate the air cushion mat (10). The method according to claim 1,
The auxiliary air injection unit 16 can be formed at a position of one air bag 11a of the cushion forming unit 23 to be formed into the air bag 11a of the cushion unit 11, A bellows injection tube 17 having a check valve 19 for injecting air is provided in the auxiliary air injection part 16 in a state where the auxiliary air injection part 16 is formed and the air cushion mat 10 is manufactured. Wherein the air-cushioning mat is attached to the air-cushioning mat. 3. The method according to claim 1 or 2,
The cushion forming part 23 has a plurality of recessed structures recessed in a structure opposed to the cushion part 11 so as to form a plurality of air bags 11a and a communication path 13, The four sides of the cushion forming portion 23 forming the cushion forming portion 11a are formed by the cutting portion 25 so that the tube 15 is compressed by the lower plate metal mold 21 and the cushion metal mold 22 to be thermally fused Wherein the cut portion (25) cuts the tube (15) to the full size of the cushion forming portion (23). A cushion portion 11 having a plurality of air bladders 11a and a communication passage 13, a lower plate portion 12 having a flat plate structure for covering the bottom surface of the cushion portion 11, A manufacturing method for manufacturing an air cushion mat (10) including an air inlet (14) provided for injecting outside air,
An injection mold designed for each of the shape of the cushion part 11 and the shape of the lower plate part 12 is prepared and a molten material melted by heating the thermoplastic rubber is injected into each injection mold, The cushion part 11 and the lower plate part 12 are separated from each other,
And bonding the injection-molded cushion part (11) and the lower plate part (12) by ultrasonic vibration in an ultrasonic bonding machine,
A vibrating negative electrode opposed to the joint surface of the cushion part 11 is provided at one side of the ultrasonic welder and a hydraulic pressure block having a shape opposite to the shape of the lower plate part 12 is provided at the other side, The cushion portion 11 to be joined on the lower plate portion 12 is fixedly secured to the lower plate portion 12 and the vibrating cathode is attached to the cushion portion 12 along the portion where the cushion portion 11 and the lower plate portion 12 are to be joined The cushion part 11 and the lower plate part 12 are connected to each other by applying ultrasound vibration to the vibrating cathode through the oscillator, Wherein the air cushion mat is joined to the air cushion mat. 5. The method of claim 4,
The auxiliary air injection unit 16 is formed at one of the air bag 11a formed in the air bag 11a of the cushion unit 11 during the injection molding of the cushion unit 11 in the injection mold A bellows injection pipe 17 having a check valve 19 for injecting air is provided in the auxiliary air injection part 16 of the cushion part 11 injection-molded by the above-described design structure, Wherein the air cushion mat is made of a synthetic resin. An air cushion mat manufactured by any one of the manufacturing methods of any one of claims 1, 2, 4, and 5. The method according to claim 6,
The air inlet port 14 of the air cushion mat 10 is provided with an inlet 18a formed to be able to inject outside air and a spring member 18c disposed on the inlet passage 18e communicating with the inlet 18a A check valve 18 having an O-ring 18d disposed on the interface between the inlet 18a and the inlet passage 18e so as to be in contact with the check ball 18b is inserted Wherein the air cushion mat is attached to the air cushion mat. The method according to claim 6,
An air circulation pipe connection port is provided at one side of the cushion part 11 separately from the air inlet port 14 of the air cushion mat 10 and an air circulation pipe 43 is connected to the air circulation pipe connection port, A circulating control box 40 having a pressure gauge, a solenoid valve, a circulating pump, a temperature sensor and a microcomputer, and a heating device 41 composed of an electric heater are mounted on the circulation pipe 43, and an air circulation pipe 43 And the air heated by the heating device (41) circulates through the circulation connection with the air inlet (14) to perform the heating function. The method according to claim 6,
An air circulation pipe connection port is provided at one side of the cushion part 13 separately from the air inlet port 14 of the air cushion mat 10 and an air circulation pipe 43 is connected to the air circulation pipe connection port, A circulation control box 40 having a pressure gauge, a solenoid valve, a circulation pump, a temperature sensor and a microcomputer and a cooling device 42 are mounted on the circulation pipe 43 and the air circulation pipe 43 is connected to the air inlet 14 And the cooling air is circulated through the cooling device 42 to perform a cooling function.

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