KR102233715B1 - Protective mat manufacturing method - Google Patents

Abstract

The present invention relates to a method of manufacturing a protective mat. More specifically, in the manufacture of a protective mat installed on the indoor floor to safely protect children and prevent interlayer noise, advantages of PE and PVC are combined so as to manufacture a protective mat which is inexpensive and safe, and has improved tactile sensation of a surface while preferentially ensuring cushion performance. Specifically, in the present invention, PE foam and PVC foam sheet having release properties are made to be effectively bonded to facilitate easy manufacturing of a product that has advantages of two different materials, and manufacturing of the mat is finished by forming an inclined part on an edge thereof so as to prevent children from tripping over a side surface of the mat and prevent foreign substances from being absorbed via the side surface. In addition, in the present invention, PE foam and PVC foam sheet are bonded using PU, and accordingly, when the PVC foam sheet is wrinkled or deformed, the shape of the PVC foam sheet can be restored to its original shape, and thus, product properties of the protective mat can be maintained continuously even when being reused after stored. Therefore, it is possible to improve reliability and competitiveness in a field of various mats used in various children′s facilities, an interlayer noise prevention field, a vehicle mat field and a field similar or related thereto, in addition to a field of protective mats, especially indoor floor mats.

Description

Protective mat manufacturing method}

The present invention relates to a method of manufacturing a protective mat, and more particularly, in manufacturing a protective mat installed on the floor indoors to safely protect children and prevent interlayer noise, PE (Poly Ethylene) and PVC (Poly Vinyl Chloride) By combining the advantages of ), it is possible to improve the feel of the surface while guaranteeing the cushioning performance as a top priority, while being inexpensive and safe.

In particular, the present invention makes it possible to effectively bond the PE foam and the PVC foam sheet having releasability, thereby making it very easy to manufacture a product having the advantages of both materials, and forming an inclined portion at the edge of the mat to finish. The present invention relates to a method of manufacturing a protective mat capable of preventing children from tripping over the side of the mat and preventing foreign substances or the like from being absorbed to the side by processing.

In areas with high population density, large-scale residential complexes such as apartments are formed, and in recent years, interfloor noise has emerged as a major problem in these apartments.

Accordingly, various indoor interior products such as building materials and floor mats have been developed to solve the interfloor noise problem.

In particular, the floor mat is made of foam of various materials, and is mainly made of PE (Poly Ethylene) or PVC (Poly Vinyl Chloride).

In the case of PE, it is used in various product lines due to its advantages of being easy to process, light, odorless, and cheap, and is known as a relatively safe material, and is widely used in children's toys.

However, when PE is used as a surface material, it has a disadvantage that its durability is weak and its touch and print quality are not good compared to PVC.

On the other hand, PVC has good touch and good print quality, so it has been used as a play mat or floor mat for children from the past, but the material is heavy, has a peculiar smell, and wrinkles easily occur, resulting in a sharp decline in product quality. There is a disadvantage in that there is a limitation in the applicable product line.

In order to combine the advantages of PE and PVC and solve the shortcomings, it is best to attach the PVC sheet to the surface of the mat made using PE foam, but it is difficult to attach directly due to the releasability of the two materials. there was.

Registered Utility Model Publication No. 20-0477822'Floor Mat'

In order to solve the above problems, the present invention provides advantages of PE (Poly Ethylene) and PVC (Poly Vinyl Chloride) in manufacturing a protective mat installed on the indoor floor to safely protect children and prevent inter-floor noise. It is an object of the present invention to provide a method of manufacturing a protective mat capable of improving the feel of the surface while ensuring the cushioning performance as a top priority while being inexpensive and safe.

In particular, the present invention makes it very easy to manufacture a product having the advantages of two materials by effectively adhering the PE foam with releasability and the PVC foam sheet, and finishes by forming an inclined part at the edge of the mat. By doing so, it is an object of the present invention to provide a method of manufacturing a protective mat capable of preventing children from tripping over the side of the mat and preventing foreign substances or the like from being absorbed to the side.

In addition, in the process of bonding the PE foam and the PVC foam sheet, the present invention uses PU (Poly Urethane) of similar properties, so that the PE foam and the PVC foam sheet can be easily adhered, as well as wrinkles or wrinkles on the PVC foam sheet. When deformation occurs, it is an object to provide a protective mat manufacturing method that can restore the PVC foam sheet to its original shape by using the restoring force of PU.

In order to achieve the above object, the method of manufacturing a protective mat according to the present invention comprises: a lamination mat manufacturing step of manufacturing a lamination mat by laminating at least two sheets formed of different materials; And a finishing step of forming an inclined portion by finishing the edge of the laminated mat.

In addition, in the laminated mat, an uppermost layer may be formed of a highly durable waterproof cushion sheet, and a lower layer of the uppermost layer may be formed of a highly elastic foam.

In addition, the highly elastic foam may be formed of PE (Poly Ethylene) or EVA (Ethylene Vinyl Acetate Copolymer), and the waterproof cushion sheet may be formed of PVC (Poly Vinyl Chloride).

In addition, the step of manufacturing the laminated mat may include a laminating process of adhering a waterproof cushion sheet made of PVC to the outer surface of a high elastic foam made of PE or EVA.

In addition, the lining process may include an adhesive application process of applying an adhesive to the outer surface of the high elastic foam foam made of PE material; An adhesive curing process of curing the adhesive into a gel state; And a sheet attaching process of pressing and attaching the waterproof cushion sheet made of PVC to the gel-like adhesive.

In addition, the lamination mat may be formed by laminating at least three sheets, and an open structure foam having high resilience may be further formed between the high elastic foam foam and the waterproof cushion sheet.

In addition, the open structure foam may include at least one of a poly urethane (PU) foam and a memory foam.

In addition, the lamination mat may be formed by laminating at least three sheets, and the lowermost layer may be formed of a non-slip film or a highly durable waterproof cushion sheet.

In addition, the finishing step may include an edge heating process of heating the edge of the laminated mat in a heating zone disposed along the edge of the laminated mat when the laminated mat is supplied; And an edge cooling molding process of forming a straight inclined portion by pressing an edge of the previously heated laminated mat with a cooling mold in a cooling molding zone formed behind the heating zone.

In addition, the finishing step may include an edge high-frequency molding process of forming a curved inclined portion by press-forming with a high-frequency hot mold in a high-frequency molding zone disposed along the edge of the laminated mat when the laminated mat is supplied. .

By the above solution, the present invention provides the advantages of PE (Poly Ethylene) and PVC (Poly Vinyl Chloride) in manufacturing a protective mat installed on the indoor floor to safely protect children and prevent inter-floor noise. By combining it, there is an advantage of being able to improve the feel of the surface while ensuring the cushioning performance as the top priority, while being inexpensive and safe.

Through this, the present invention can greatly improve product properties such as safety, price competitiveness, and reliability of the protective mat.

In particular, the present invention has the advantage of making it very easy to manufacture a product having the advantages of two materials by effectively bonding the PE foam with the releasability and the PVC foam sheet.

Accordingly, the present invention can effectively operate the manufacturing process of the protective mat, through which there is an effect of improving the productivity of the product and minimizing the manufacturing cost of the product.

In addition, according to the present invention, by forming an inclined portion at the edge of the mat to finish, it is possible to prevent children from falling over the side of the mat and at the same time preventing foreign matters from being absorbed to the side.

In addition, in the process of bonding the PE foam and the PVC foam sheet, the present invention uses PU (Poly Urethane) of similar properties, so that the PE foam and the PVC foam sheet can be easily bonded, as well as wrinkles on the PVC foam sheet. However, when deformation occurs, there is an advantage that the PVC foam sheet can be restored to its original shape by using the restoring power of PU.

Accordingly, the present invention is advantageous in that even when the protection mat is stored and reused, wrinkles or deformations do not occur in the surface of the PVC foam sheet, so that product properties can be continuously maintained.

Therefore, it is possible to improve reliability and competitiveness in similar or related fields, such as the field of protection mats, especially the field of indoor floor mats, as well as the fields of various mats used in various infant facilities, as well as the field of interlayer noise prevention or the field of vehicle mats. .

1 is a flowchart showing an embodiment of a method for manufacturing a protective mat according to the present invention.
FIG. 2 is a flowchart illustrating a specific embodiment of step'S100' shown in FIG. 1.
3 is a flowchart illustrating specific embodiments of step'S200' shown in FIG. 1.
FIG. 4 is a diagram specifically illustrating the steps of FIG. 1.
5 is a diagram specifically illustrating the process of FIG. 2.
6 is a flowchart illustrating another specific embodiment of step'S100' shown in FIG. 1.
7 and 8 are views specifically explaining the process shown in FIG. 3.

Examples of the method for manufacturing the protective mat according to the present invention can be applied in various ways, and hereinafter, the most preferred embodiments will be described with reference to the accompanying drawings.

1 is a flowchart showing an embodiment of a method for manufacturing a protective mat according to the present invention, and FIG. 4 is a diagram specifically illustrating the steps of FIG. 1.

Referring to Figure 1, the protective mat manufacturing method includes a laminated mat manufacturing step (S100) and a finishing step (S200).

In the laminated mat manufacturing step (S100), at least two sheets formed of different materials are laminated to produce the laminated mat 100 as shown in FIG. 4.

For example, the laminated mat 100 may have a highly durable waterproof cushion sheet 110 formed on the uppermost layer, as shown in FIG. 4, and the lower layer of the uppermost layer (intermediate layer when the laminated mat is composed of three or more layers) There may be formed of a high elastic foam (120).

In addition, when the lamination mat 100 is formed by stacking at least three sheets, the lowermost layer may be formed of an anti-slip film 130 or a waterproof cushion sheet 110 having a high durability.

In this case, the lowermost layer may be selectively applied, and of course, it may be composed of four or more layers according to the needs of those skilled in the art.

For example, the lower layer of the uppermost layer of the high elastic foam 120 may be formed of PE (Poly Ethylene) or EVA (Ethylene Vinyl Acetate Copolymer), and the uppermost waterproof cushion sheet 110 is PVC (Poly Vinyl Chloride). ) Can be formed.

In addition, the lowermost layer may also be formed of a PVC foam sheet.

In the finishing step (S200), the edge of the laminated mat 100 manufactured as described above may be finished to form an inclined portion (a), and in this way, the inclined portion (a) is formed by the waterproof cushion sheet (110). When finished, it is possible to prevent children from stumbling over the side of the mat and at the same time preventing foreign matters from being absorbed to the side.

This inclined portion (a) will be described in more detail below.

On the other hand, as discussed above, PE or EVA and PVC having different properties are very difficult materials to be bonded by a general method.

Hereinafter, a method of bonding two materials having completely different properties will be described.

FIG. 2 is a flowchart illustrating a specific embodiment of step'S100' shown in FIG. 1, and FIG. 5 is a diagram specifically illustrating the process of FIG. 2.

2, the laminated mat manufacturing step (S100) includes a laminating process (S110) of adhering the waterproof cushion sheet 110 of PVC material to the outer surface of the high elastic foam 120 of PE material or EVA material. I can.

In addition, the laminating process (S110) may include an adhesive application process (S111), an adhesive curing process (S112), and a sheet attaching process (S113).

Looking at this in detail, after applying the adhesive 140 to the outer surface of the high elastic foam 120 of the PE material as shown in Figure 5 (S111), after a certain period of time, a part of the applied adhesive 140 It may be introduced between the high elastic foam 120, the adhesive 140 is cured in a gel state thereafter, the introduced portion may be formed as a protrusion 141 of an atypical shape (S112).

In this way, when a part of the adhesive 140 is formed of the protrusion 141 of an atypical shape, it means that the adhesive 140 can be structurally bonded to the outer surface of the highly elastic foam 120.

Therefore, when the PVC waterproof cushion sheet 110 is pressed and attached to the gel-like adhesive 140 firmly bonded to the outer surface of the high elastic foam 120 (S113), the outer thermal insulation layer of the PE material It is possible to firmly couple the waterproof cushion sheet 110 of PVC material to (120).

6 is a flowchart illustrating another specific embodiment of step'S100' shown in FIG. 1.

Referring to FIG. 6, in the laminated mat 100, an open structure foam 150 having high resilience may be further formed between the high elastic foam 120 and the waterproof cushion sheet 110. For example, the open structure foam may include at least one of Poly Urethane (PU) foam and memory foam.

Specifically, after heating the upper surface of the open structure foam 150 to form the upper melting surface 151, the waterproof cushion sheet 110 may be adhered to the upper melting surface 151.

Thereafter, the lower surface of the open structure foam 150 to which the waterproof cushion sheet 110 is adhered is heated to form a lower melting surface 152, and then the high elastic foaming foam 120 is formed by using the lower melting surface 152. The open structure foam 150 may be adhered to the upper part.

Finally, the anti-slip film 130 or the highly durable waterproof cushion sheet 130 may be adhered to the lower surface of the highly elastic foam 120 according to the type of product and the request of a person skilled in the art.

3 is a flowchart illustrating specific embodiments of step'S200' shown in FIG. 1, and FIGS. 7 and 8 are diagrams specifically explaining the process shown in FIG. 3.

3, the finishing treatment step (S200) includes a cooling molding method including an edge heating process (S211) and an edge cooling molding process (S212), and a high frequency molding method including the edge high frequency molding process (S221). can do.

First, looking at the cooling molding method, when the laminated mat 100 produced in the laminated mat manufacturing step (S100) is supplied through the supply roll 210 as shown in FIG. 7A, the edge of the laminated mat 100 The edge of the stacked mat 100 may be heated in the heating zone 230 disposed along the line (S211).

Thereafter, the laminated mat 100 with heated edges is in the cooling molding zone 240 formed at the rear of the heating zone 230, while the edge of the previously heated laminated mat 100 is press-molded with a cooling mold, as shown in FIG. As shown in (b), a straight inclined portion a1 may be formed.

In other words, when the edge of the waterproof cushion sheet 110 supplied with heat from the heating zone 230 expands while being press-molded with a cooling mold to form the outer surface of the inclined part a1, sewage from the outside through the side part It can prevent foreign substances such as the back from being absorbed.
As shown in Figure 7, the supply roll is supplied by winding the stacked mat already stacked in the stacking mat manufacturing step, and the stacking mat wound on the supply roll is continuously supplied in the direction B, which is the direction of progression. A continuous inclined portion is formed on the side surface of the stacking mat while passing through the heating zone and the cooling forming zone provided on both sides of the phosphorus B direction, and the stacking mat A in which the inclined portion is formed may be rewound on the winding roll.

In this way, the lamination mat 100 in which the straight inclined portion a1 is formed at the edge portion may be wound on the winding roll 220 and transported to a subsequent process.

Next, looking at the high frequency molding method, when the laminated mat 100 produced in the laminated mat manufacturing step (S100) is supplied through the supply roll 210 as shown in FIG. 8A, the laminated mat 100 In the high-frequency molding zone 250 disposed along the edge, a high-frequency hot mold is pressed to form a curved inclined portion a2 as shown in FIG. 8B (S221).

In addition, the laminated mat 100 in which the curved inclined portion a2 is formed at the edge portion may be wound on the winding roll 220 and transported to a subsequent process.

As described above, the edge of the laminated mat 100 of the present invention can be finished by two methods, and the configuration of a heater, a cooling molding device, a high frequency molding device, etc. installed in the corresponding zone of each process is required by those skilled in the art. Since it can be applied in various ways, it is not limited to a specific one as long as it can perform the process of the present invention.

In the above, the method for manufacturing the protective mat according to the present invention has been described. It will be appreciated that the technical configuration of the present invention can be implemented in other specific forms without changing the technical spirit or essential features of the present invention by those skilled in the art to which the present invention pertains.

Therefore, the embodiments described above are illustrative in all respects, and should be understood as non-limiting.

A: Protective mat a: Inclined part
100: laminated mat
110: waterproof cushion sheet 120: foam foam
130: non-slip sheet
140: adhesive 141: protrusion
150: open structure foam 151: upper melting surface
152: lower melting surface
210: supply roll 220: winding roll
230: heating zone 240: cooling forming zone
250: high frequency molding zone

Claims (10)

A lamination mat manufacturing step of laminating at least two sheets formed of different materials to manufacture a lamination mat; And
Including; a finishing step of forming an inclined portion by finishing the edge of the laminated mat in the laminated state in the laminated mat manufacturing step,
The laminated mat,
The top layer is formed of a highly durable waterproof cushion sheet,
The lower layer of the uppermost layer is formed of a highly elastic foam,
The highly elastic foam is formed of PE (Poly Ethylene) or EVA (Ethylene Vinyl Acetate Copolymer),
The waterproof cushion sheet is formed of PVC (Poly Vinyl Chloride),
The step of manufacturing the laminated mat,
Including; a laminating process of adhering a waterproof cushion sheet made of PVC material to the outer surface of a high elastic foam foam made of PE material or EVA material,
The laminating process,
Adhesive application process of applying an adhesive to the outer surface of the high elastic foam foam made of PE or EVA material;
An adhesive curing process of curing the adhesive into a gel state; And
Including; a sheet attaching process in which a waterproof cushion sheet made of PVC material is pressed and attached to a gel-like adhesive,
The adhesive curing process,
After a certain period of time has elapsed, a part of the adhesive is cured in a gel state in a state in which it soaks into the outer surface of the highly elastic foam to form a protrusion of an atypical shape,
The high elastic foam foam,
Is coupled to the protrusion,
The laminated mat,
At least three sheets are stacked and formed,
Between the highly elastic foam and the waterproof cushion sheet,
An open structure foam with high resilience is further formed,
The open structure foam,
Including at least one of PU (Poly Urethane) foam and memory foam,
The laminated mat,
At least three sheets are laminated and formed,
The lowermost layer is formed of an anti-slip film or a highly durable waterproof cushion sheet,
The finishing process step,
An edge heating process of heating the edge of the laminated mat in a heating zone disposed along the edge of the laminated mat when the laminated mat is supplied; And
In the cooling forming zone formed at the rear of the heating zone, the edge cooling forming process of forming a straight inclined portion by press-forming the edge of the previously heated stacking mat with a cooling mold; Including,
The laminated mat,
In the stacking mat manufacturing step, it is wound on a supply roll in a state already stacked and continuously supplied by the supply roll in the forward direction,
The edge is heated while passing through the heating zone provided on both sides of the traveling direction,
The inclined portion is formed continuously at the edge while passing through the cooling forming zone provided on both sides of the proceeding direction,
The protective mat manufacturing method, characterized in that the laminated mat having the inclined portion is wound on a winding roll. delete delete delete delete delete delete delete delete delete

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