KR101507983B1 - Cushion and cushion manufacturing method - Google Patents

Abstract

The present invention relates to a method of manufacturing a sponge cushion, and more particularly, to a method of manufacturing a sponge cushion by forming a thermo-polyurethane (TPU) film on a surface of a first mold having a shape and a plurality of fine- A step A for fixing a finish material formed of one of a mesh, a fiber and a nonwoven fabric to one surface of a second mold; A step C of injecting a polyurethane foaming resin stock solution between the thermoplastic polyurethane film and the finish paper; And a step D in which the finishing paper and the film paper are bonded to the cured soft polyurethane foaming resin while the impregnated polyurethane foaming resin undiluted solution seeps into the finishing paper and hardens, wherein the outer surface of the polyurethane foaming resin And a step of bonding the thermoplastic polyurethane film and the finishing paper to prevent the tearing of the polyurethane foaming resin and preventing generation of dust from the polyurethane foaming resin. Lt; / RTI > As a result, the thermoplastic polyurethane film and the finish paper can be bonded to the outer surface of the polyurethane foam resin at one time, the polyurethane foam resin can be prevented from being contaminated or broken, and various shapes can be printed on the outer surface of the cushion.

Description

Technical Field [0001] The present invention relates to a cushion and a cushion manufacturing method,

The present invention relates to a method of manufacturing a sponge cushion, and more particularly, to a method of manufacturing a sponge cushion which can prevent a polyurethane foam resin (sponge) from being torn and dust from being generated from a polyurethane foam resin, To a cushion cushion manufacturing method in which physical strength that can be manufactured by bonding a cover that protects the polyurethane foam resin at one time can be printed.

A typical sponge cushion is made by injecting a polyurethane foaming resin solution into a mold and curing it to form a sponge block. The sponge block thus made is covered with a cover made of leather, synthetic resin or fiber to make a cushion.

Such a conventional cushion is well known in the prior art publication No. 20-2011-0003680, that is, the sponge block is vulnerable to an external force, dust is generated, and the sponge block is covered with a cover on the outer surface of the sponge block.

Therefore, a manufacturing process is required to manufacture a sponge cushion separately and cover the sponge block with a sponge block, which results in a long manufacturing time and an increase in cost.

Especially, in the process of using the cushion, the sponge block and the cover are rubbed against each other to generate dust from the sponge block. For example, if the cover is detached from the sponge block for cleaning, the dust generated from the sponge block may be blown out during the separation, and dust may enter the body at this time.

Further, the cover can not be folded or the volume can not be reduced due to the cover, and the portability also deteriorates.

The present invention has been conceived to solve the problems of the prior art described above, and it is an object of the present invention to provide a thermoplastic polyurethane film which can be bonded to the outer surface of a polyurethane foaming resin at one time with a finish paper and without being contaminated or broken A method of manufacturing a cushion cushion that can print various shapes on the outer surface of a cushion, improve the productivity by shortening the manufacturing time, and improve the physical strength which is light and can be folded to reduce the volume, The purpose is to provide.

It is another object of the present invention to provide a cushion cushion improved in physical strength produced by the above-described manufacturing method.

In order to achieve the above object,

(TPU: Thermo Polyurethane) film is adhered to a surface of a first mold having a plurality of fine adsorption holes formed on the surface of the mold, A step B for fixing a finish material formed on at least one of the mesh, the fiber, and the nonwoven fabric to one surface of the mold; and a step for bonding the polyurethane foam resin raw solution to the thermoplastic polyurethane film and the thermoplastic polyurethane film in a state in which the first mold and the second mold are in close contact with each other. A step C for injecting between the finishing papers; And a step D of bonding the polyurethane foamed resin to the polyurethane flexible foam formed by curing the finish paper and the film paper while being immersed and hardened in the finish paper, A method for manufacturing a cushion cushion improved in physical strength, characterized in that a thermoplastic polyurethane film and the finish paper are integrally joined together to prevent the polyurethane flexible foam from tearing and to prevent dust from being generated from the polyurethane flexible foam Lt; / RTI >

Further, the method may further include a step A-0 of printing a shape on the thermoplastic polyurethane film before the step (A).

The method may further include a step A-1 of preheating the first mold and the second mold such that the temperature of the first mold and the second mold is 40 [deg.] C to 50 [deg.] C before step C, It is possible to prevent the urethane foamed resin raw stock from being quenched and partially cured.

The thermoplastic polyurethane film may be stretched before the step A so that the thermoplastic polyurethane film is closely contacted with the edge of the first mold and then pressed against the periphery of the closely attached thermoplastic polyurethane film by a fixing frame corresponding to the rim of the first mold, And fixing the film to the edge of the first mold.

In the step A,

The air between the first mold and the thermoplastic polyurethane film is discharged to the outside of the first mold through the suction holes in the state of step A-1, so that the thermoplastic polyurethane film forms the shape of the first mold Can be brought into close contact with the surface.

In the step C,

When the first mold and the second mold are in close contact with each other, the periphery of the thermoplastic polyurethane film and the periphery of the finish are brought into close contact with each other, and the polyurethane foaming resin stock solution to be injected is completely wrapped by the thermoplastic polyurethane film and the finish paper It is possible to prevent the polyurethane flexible foam from being exposed to the outside.

Further, the method may further include an E step of cutting the finishing paper and the thermoplastic polyurethane film remaining after being joined with the polyurethane flexible foam after the step D).

In the step C,

The polyurethane foamed resin raw material solution can be rapidly injected within 2 seconds and the polyurethane foamed resin raw material solution injected in the step D can be simultaneously cured in the entire region.

In the step (D)

The polyurethane foam resin homogenate can be uniformly cured by passing the stock solution of the polyurethane foam resin for 8 to 12 minutes.

In order to achieve the above object, the present invention is also achieved by a cushion cushion improved in physical strength manufactured by the above-described manufacturing method.

According to the present invention, the thermoplastic polyurethane film and the finish paper corresponding to the cover can be bonded to the outer surface of the polyurethane foam resin at one time without a separate adhesive. As a result, the cushion manufacturing time can be shortened and the productivity can be further improved.

In addition, it is possible to prevent the polyurethane foam resin from being exposed to the outside, to prevent the cushion from being contaminated, and to prevent the polyurethane foam resin from being broken.

In addition, the cushion can be produced after printing various shapes on the thermoplastic polyurethane film, thereby improving the feel of the cushion.

Further, the thermoplastic polyurethane film has high tensile strength, tear strength and physical strength, so that the cushion can be prevented from tearing.

In addition, since soft polyurethane foam resin with excellent low specific gravity, softness, excellent elasticity and restoring force is used, the cushion is light and folded to reduce the volume, so it is easy to store and carry.

Further, by joining the finish paper to the bottom surface of the polyurethane foam resin, the inside air of the polyurethane foam resin can be easily discharged through the finish paper, and the restoring force of the cushion is excellent because the outside air is easily introduced.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a block diagram showing schematic steps of a method for manufacturing a cushion cushion in which physical strength is improved according to an embodiment of the present invention. FIG.
2 to 4 are views schematically showing a process of manufacturing a cushion by a method of manufacturing a cushion cushion having improved physical strength according to an embodiment of the present invention.
5 is a cross-sectional view of a cushion produced by a method of manufacturing a cushion cushion with improved physical strength according to an embodiment of the present invention.

The preferred embodiments of the present invention will be described in more detail with reference to the accompanying drawings, in which the technical parts already known will be omitted or compressed for the sake of brevity.

1 to 5, a method of manufacturing a cushion cushion improved in physical strength according to an embodiment of the present invention includes a first mold 1 corresponding to a lower mold, a fixing frame 3, A thermoplastic polyurethane (TPU) film 4 (hereinafter referred to as a film 4), and a finish paper 5 formed of a mesh, a fiber and a nonwoven fabric, And the step A, the step B, the step C, and the step D, to manufacture the cushion 100 using the polyurethane foamed resin solution 6 and the polyurethane foamed resin solution 6 (hereinafter referred to as the " Here, it may further comprise steps A-0, A-1, A-2 and E.

Prior to the description, the thermoplastic polyurethane film (4) uses a film (4) having excellent overall physical strength such as tensile strength, tear strength and tear strength, and the finish paper (5) is at least one of a mesh, And the polyurethane foam resin raw liquid 6 uses a raw liquid 6 excellent in low specific gravity, softness, excellent elasticity, and restoring force. Here, since the film 4, the finishing paper 5, and the undiluted solution 6 are well-known products, a detailed description will be omitted.

Step A-0 (S1) is a step of printing various patterns such as patterns, figures, figures and characters on the film 4. In other words, since the processed film 4 is formed with a curvature and is difficult to print, various shapes are printed on the film 4 before processing for convenience of printing.

Step A-1 (S3) is a step of preheating the first mold 1 and the second mold 2 at 40 ° C to 50 ° C. That is, when the temperature of the first mold 1 and the second mold 2 is low and the original liquid 6 is injected while the first mold 1 and the second mold 2 are in close contact with each other, Curing can be started while cooling due to the low temperatures of the first mold 1 and the second mold 2. [ This is because the hardness of the inner and outer surfaces of the polyurethane flexible foam 7 (hereinafter referred to as " flexible foam 7 ") formed by the partial hardening of the raw liquid 6 and the hardening of the raw liquid 6 can be changed . The elasticity, the restoring force and the softness are changed when the hardness of the portion of the soft foam 7 is changed. Therefore, the first mold 1 and the second mold 2 are adjusted to have a temperature similar to that of the undiluted solution 6. [ Accordingly, the flexible foam 7 having the elasticity, the restoring force and the softness can be formed by preheating the first mold 1 and the second mold 2. [

Step A-2 (S5) is a step of spreading the film 4 printed with the shape and bringing the film 4 into close contact with the upper surface of the first mold 1 and then pressing the film (3) with the fixing frame 3 corresponding to the rim of the first mold 1 4 is pressed to fix the film 4 to the first mold 1. At this time, the space between the peripheral region of the film 4 and the first mold 1 is sealed. Here, the inner surface of the first mold 1 is formed in an embossed shape, and a plurality of fine suction holes are formed. A description thereof will be described later.

In step A9, a space is formed between the film 4 and the first metal mold 1 after step A-2. The film 4 and the first metal mold 1 are passed through the suction hole of the first metal mold 1, And sucking the internal air between the molds 1 and discharging them to the outside of the first mold 1. At this time, a vacuum state is maintained between the film 4 and the first metal mold 1 after the internal air is sucked. As a result, the film 4 is stretched and the film 4 is brought into close contact with the surface of the first mold 1 on which the embossing is formed.

Step B7 is a step of fixing the finish paper 5 to the bottom surface of the second metal mold 2 and fixing them. At this time, in one region of the finishing paper 5, a hole through which the undiluted solution 6 is injected is formed, and the finishing paper 5 is fed in a state in which the hole of the finishing paper 5 and the injection port of the second metal mold 2 are aligned And fixed to the second mold 2.

Here, there is no priority among the steps A-1, A, and B, and any step may be processed first.

C step S11 is a step in which the first mold 1 and the second mold 2 are brought into close contact with each other after the step A and the step B and the first mold 1 and the second mold 2 are in close contact with each other And injecting the undiluted solution 6 through the injection port of the second mold 2. At this time, the raw liquid 6 injected in close contact with the circumferential region of the finishing paper 5 and the circumferential region of the film 4 is injected into a space formed between the finishing paper 5 and the film 4, Is injected within 2 seconds. Thus, the raw liquid 6 is rapidly injected and the injected raw liquid 6 is simultaneously hardened over the entire area, so that the flexible foam 7 of a uniform quality can be formed. In addition, the remaining portion except for the hole of the finishing paper 5 can prevent the soft foam 7, which is formed by curing the raw fluid 6 to be described later, from being exposed to the outside, so that the soft foam 7 can be prevented from being damaged or contaminated.

In step D13, after the C step, the raw liquid 6 is cured to form the flexible foam 7, and the film 4 and the finish paper 5 are integrally joined to the periphery of the flexible foam 7, . At this time, the injected raw liquid 6 is aged for 8 to 12 minutes. That is, since the raw liquid 6 and the film 4 have the same or similar chemical properties, the raw liquid 6 is hardened without a separate adhesive and the flexible foam 7 and the film 4 are strongly bonded, The raw liquid 6 is hardened and the soft foam 7 and the finishing paper 5 are strongly bonded to each other without the adhesive agent as the raw liquid 6 seeps into the finishing paper 5. Accordingly, the film 4, the flexible foam 7, and the finish paper 5 can be integrally bonded together without the separate bonding process, and the flexible foam 7 having the uniform inner and outer materials can be obtained .

Step E15 is a step of releasing the product to which the flexible foam 7, the film 4 and the finish paper 5 have been bonded from the first mold 1 after the step D, (4) and the finish paper (5) are combined and the remaining film (4) and the finish paper (5) are cut with the cutter (E). Thus, the cushion cushion 100 having improved physical strength is completed.

Although it has been described above that the film 4 is adsorbed and the film 4 is brought into close contact with the first metal mold 1 in the step A described above, the film 4 is stretched by the injection pressure of the raw liquid 6, It may be adhered to the mold 1. At this time, the inner air between the film 4 and the first metal mold 1 may be discharged to the outside of the first metal mold 1 through the suction holes 11 while the film 4 is stretched.

Therefore, the method of manufacturing a cushion cushion improved in physical strength according to an embodiment of the present invention can bond the film, the flexible foam, and the finish paper at the same time, thereby shortening the manufacturing process and manufacturing time of the cushion and improving the productivity.

Thus, the cushion cushion 100 improved in physical strength manufactured by the manufacturing method of the present invention can be easily stored and carried because the volume thereof is reduced by several times or several tens times when folded, and it is possible to easily print various shapes, Very good, lightweight, soft and resilient. In addition, it has excellent physical strength such as tensile strength, tear strength and tear strength, and is environmentally friendly because it is resistant to contamination and prevents generation of dust in a flexible foam. In addition, the cushion can be manufactured in various forms, and the portion touching the floor can be prevented from tearing the cushion due to excellent strength and abrasion resistance due to the finishing paper, The resilience of the foam is excellent. Further, the upper surface is formed by embossing, and even when sitting on the cushion, the air circulation is good between the embossings and can be used comfortably.

In describing the present invention described above, the same reference numerals are used for the same configurations even if the embodiments are different, and the description thereof may be omitted if necessary.

While the present invention has been particularly shown and described with reference to exemplary embodiments thereof, it is to be understood that the invention is not limited to the disclosed exemplary embodiments. Shall not be construed as being understood. Therefore, those skilled in the art will appreciate that various modifications, additions and substitutions are possible, without departing from the scope and spirit of the invention as disclosed in the accompanying claims. The present invention is not limited thereto.

One; The first mold
11; Adsorption ball
2; The second mold
3; A fixed frame
4; Film (thermoplastic polyurethane film)
5; Finishing area
6; Stock solution (polyurethane foam resin solution)
7; Flexible foam (polyurethane flexible foam)
E; Cutter
100; A cushion

Claims (10)

(A) a step of adsorbing a thermoplastic polyurethane (TPU) film on a surface of a first mold having a plurality of fine adsorption holes formed on the surface of the mold and fixing the thermoplastic polyurethane film on the mold;
A step B of fixing the injection hole to the second mold with the injection hole being aligned with the hole formed in the finish sheet, providing a finish paper having a hole formed in one area and having at least one of mesh fiber and nonwoven fabric, ;
A step C of injecting a polyurethane foamed resin raw liquid into the space between the thermoplastic polyurethane film and the finish paper through an injection port formed in the second mold in a state in which the first mold and the second mold are in close contact with each other; And
And a step (D) of bonding the polyurethane foamed resin raw material injected to the polyurethane foamed foam formed by curing the finish paper and the thermoplastic polyurethane film while being impregnated and hardened on the finish paper,
Characterized in that the thermoplastic polyurethane film and the finishing paper are integrally joined to the outer surface of the polyurethane flexible foam to prevent the polyurethane flexible foam from tearing and to prevent dust from being generated from the polyurethane flexible foam A method of manufacturing a cushion cushion improved in physical strength.
The method according to claim 1,
Further comprising a step A-0 of printing a shape on the thermoplastic polyurethane film before the step (A).
The method according to claim 1,
And A-1 step of preheating the first mold and the second mold to a temperature of 40 ° C to 50 ° C before the step C,
Wherein the polyurethane foaming resin solution to be injected is rapidly cooled by the first mold and the second mold to prevent partial hardening.
The method according to claim 1,
The thermoplastic polyurethane film is stretched before the step A and is brought into close contact with the rim of the first mold, and then the thermoplastic polyurethane film is pressed around the closely attached thermoplastic polyurethane film by a fixing frame corresponding to the rim of the first mold, And fixing the cushion cushion to an edge of the first mold.
5. The method of claim 4,
In the step A,
The air between the first mold and the thermoplastic polyurethane film is discharged to the outside of the first mold through the adsorption hole in the state of step A-2, so that the thermoplastic polyurethane film forms the shape of the first mold Wherein the cushion cushion is brought into close contact with the surface of the cushion cushion.
The method according to claim 1,
In the step C,
When the first mold and the second mold are in close contact with each other, the periphery of the thermoplastic polyurethane film and the periphery of the finish are brought into close contact with each other, and the polyurethane foaming resin stock solution to be injected is completely wrapped by the thermoplastic polyurethane film and the finish paper Wherein the polyurethane flexible foam is prevented from being exposed to the outside.
The method according to claim 1,
Further comprising a step (E) of cutting the finished paper and the thermoplastic polyurethane film remaining after joining with the polyurethane flexible foam after the step (D).
The method according to claim 1,
In the step C,
Wherein the polyurethane foamed resin raw material solution is rapidly injected within 2 seconds and the polyurethane foamed resin raw material solution injected in the step (D) is cured simultaneously in all areas.
The method according to claim 1,
The step (D)
Wherein the polyurethane foamed resin raw solution is uniformly cured by passing the raw polyurethane foamed resin solution for 8 to 12 minutes.
A cushion cushion improved in physical strength produced by the manufacturing method according to any one of claims 1 to 9.

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