KR102383614B1 - Method for manufacturing breathable cushion mat and Breathable mat manufactured by the method - Google Patents

Abstract

The present invention relates to a method for manufacturing a buffer mat having air permeability and a buffer mat manufactured by the method. A foam cell preparation step of preparing a foam cell; An input step of putting the prepared foam cells into the mold; It consists of including a molding step of pressing the foam cell put into the mold to shape it and applying heat at the same time to melt the surface of the foam cell and make it fusion-bonded with each other.
The buffer mat manufacturing method of the present invention having the air permeability of the present invention as described above, because individual foam cells can be integrated without having to use a binder, it is eco-friendly, the manufacturing process is simple, and since the binder is removed, it is possible to manufacture a lightweight buffer mat. In addition, the cushioning mat of the present invention has sufficient voids between the spherical foam cells integrated through thermal fusion, so that moisture does not fill the inside, and it has excellent shock absorption ability and elastic restoring force. In addition, since no binder is used, it is eco-friendly and has no binder smell, so it can be used without burden. Since the unit foam cell itself is integrated, it is not easily cracked or torn even after long use. Furthermore, the cushioning mat of the present invention may be used in a cushioning seat inside a safety helmet in an industrial field, a bicycle or horseback riding saddle, a car flooring material of a vehicle, or water lifesaving equipment.

Description

Method for manufacturing breathable cushion mat and buffer mat manufactured by the method {Method for manufacturing breathable cushion mat and Breathable mat manufactured by the method}

The present invention relates to a breathable buffer mat, and more particularly, to a buffer mat manufactured by the method, which is environmentally friendly, light and excellent in shock absorption without using a binder, and has breathability.

In a multi-story apartment building, noise between floors is very stressful for the downstairs household and can lead to disputes between neighbors. Such inter-floor noise includes air-transmitted noise and impact noise. Air-transmitted noise is, for example, audio or television output sound or piano sound transmitted through air, and impact noise is the noise of dropping a hard object on the floor. This is the noise made when dropping or when a child thumps and runs. The impact noise is transmitted through the slab that separates the upper and lower generations, that is, the floor of the upper floor or the ceiling of the lower floor.

Various methods are applied to minimize the noise between floors due to the impact noise. For example, in a family with running children, carpets or cushioning mats are widely spread in the living room, etc. The cushioning mat dampens the shock when the child runs, thereby reducing the impact noise to some extent.

However, the carpet has a disadvantage that it cannot realistically expect a noise-blocking effect due to its narrow width, and the mat, taking the form of a simple sponge, does not have a very good shock absorption ability and is deformed as it is used for a long time.

As a background technology for blocking noise between floors, Korean Patent Publication No. 10-2015-0107192 (mat for preventing noise between floors) has been disclosed.

In the disclosed mat, in a mat body having a predetermined shape, an upper groove of a certain length is formed on the upper surface of the mat body to disperse vibrations generated by impact, and a constant length is formed so that vibrations moving along the upper groove are canceled on the lower surface. The length of the lower groove is formed, and the vertical vibration applied from the upper part of the mat body is primarily dispersed while moving along the upper groove of the upper surface and is reduced. The secondary dispersion is reduced while moving, and the vibration moving along the upper groove of the upper surface is offset by the vibration moving along the lower groove of the lower surface and has a structure in which it is reduced.

Domestic Patent Publication No. 10-2015-0107192 (mat for noise prevention between floors) Domestic Registered Patent Publication No. 10-2097485 (folding breathable mat) Domestic Registered Utility Model Publication No. 20-0360233 (Breathable Mat)

An object of the present invention is to provide a method for producing a cushioning mat having air permeability, which is environmentally friendly, a manufacturing process is simple, and a lightweight cushioning mat can be manufactured.

In addition, an object of the present invention is to provide a cushioning mat that does not contain moisture inside, has excellent shock absorption ability and elastic restoring force, can be used without burden because there is no odor of a binder, and has a long lifespan.

The method for producing a buffer mat having air permeability of the present invention as a means of solving the problems for achieving the above object is that a thermoplastic polyurethane material is foam-molded, it has elasticity and takes the form of an amorphous sphere, with respect to each other A foam cell preparation step of preparing the separated independent foam cells in advance; An input step of putting the prepared foam cells into the mold; By pressing the foam cells put into the mold, the foam cells are brought into contact with each other, and heat is applied while maintaining the voids, so that the surfaces of the neighboring foam cells are melted by heat and fused to each other. A forming step of manufacturing a; and a drying step of drying the molding obtained through the molding step, wherein the mold is a ventilable type mold, and the molding step includes; The pressing process of pressing the foam cells to take the form of a plate, and a process that proceeds simultaneously with the pressing process, by passing heated air through the gaps between the foam cells, the adjacent foam cells are fused by the heat of the air It includes a ventilation fusion process for bonding, and between the molding step and the drying step, a refrigerant is added to the molding to allow the refrigerant to pass through the pores inside the molding, thereby cooling the surface of each foam cell and also heat in the pores And a shower step of removing foreign substances is further included, the drying step; It is a process in which drying air is blown to the molding after the shower step has been completed, so that the drying air passes through the pores inside the molding to remove moisture inside the pores.

delete

delete

In addition, the mold; A lower mold that provides a molding space open to the upper portion and an exhaust hole is formed in the bottom portion, is provided so as to be able to move up and down on the upper portion of the lower mold, and has an air supply hole for discharging air introduced from the outside downward, the air It includes an upper mold with a built-in heater for heating, the pressing process; It is a process of pressing the foam cells put into the molding space of the lower mold with the upper mold to make neighboring but spaced foam cells close to each other, the ventilation fusion process; It is a process in which the air introduced into the upper mold is heated using a heater and then discharged to the lower part through the air supply hole so that the heated air passes through the gap between the foam cells and melts the surface of the foam cells to be fused.

In addition, the mold; A lower mold that provides an open molding space to the upper portion, has a built-in heater, an inlet hole for guiding outside air into the molding space, and an exhaust tube for discharging the air inside the molding space to the outside; It is installed so as to include an upper mold with a built-in heater, the pressing process; By pressing the foam cells put into the lower mold with the upper mold, it is a process of making neighboring but separated foam cells close to each other, and the ventilation fusion process includes; It may be a process of fusing the surface of the foam cell by operating a heater, and at the same time extracting air from the inside of the molding space through the exhaust tube, so that the air is exhausted through the voids between the foam cells.

In addition, the method for producing a buffer mat having air permeability of the present invention as another solution to the problem for achieving the above object is a thermoplastic polyurethane material foam-molded, taking the form of an atypical sphere, relative to each other A foam cell preparation step of preparing the separated foam cell; a heating step of continuously transferring and heating the foam cell so that the surface of the foam cell is melted; A molding step of obtaining a continuous sheet-shaped molded product of a certain width and thickness having internal voids by putting the foamed cells after the heating step into a molding roll device, and allowing the foamed cells to pass through the molding roll device and compressed; a pore securing step of receiving and passing the molded product from the molding roll device and passing air in the thickness direction of the molded product to secure voids inside the molding; and a drying step of transferring and drying the molded product having completed the step of securing the voids.

In addition, between the pore securing step and the drying step, by adding a refrigerant to the molding to allow the refrigerant to pass through the pores inside the molding, cooling the surface of each foam cell as well as a shower step of removing heat and foreign substances in the pores more included.

In addition, the buffer mat of the present invention as a means of solving the problem for achieving the above object is a thermoplastic polyurethane material foamed, has elasticity, takes the form of an amorphous sphere, and is separated from each other A foam cell preparation step of preparing and preparing an independent foam cell in advance; An input step of putting the prepared foam cells into the mold; By pressing the foam cells put into the mold, the foam cells are brought into contact with each other, and heat is applied while maintaining the voids, so that the surfaces of the neighboring foam cells are melted by heat and fused to each other. A forming step of manufacturing a; and a drying step of drying the molding obtained through the molding step, wherein the mold is a ventilable type mold, and the molding step includes; The pressing process of pressing the foam cells to take the form of a plate, and a process that proceeds simultaneously with the pressing process, by passing heated air through the gaps between the foam cells, the adjacent foam cells are fused by the heat of the air It includes a ventilation fusion process for bonding, and between the molding step and the drying step, a refrigerant is added to the molding to allow the refrigerant to pass through the pores inside the molding, thereby cooling the surface of each foam cell and also heat in the pores And a shower step of removing foreign substances is further included, the drying step; It is manufactured through the process of blowing drying air to the molding after the shower step has been completed so that the drying air passes through the pores inside the molding to remove moisture inside the pores.

delete

delete

The buffer mat manufacturing method of the present invention having the air permeability of the present invention as described above, because individual foam cells can be integrated without having to use a binder, it is eco-friendly, the manufacturing process is simple, and since the binder is removed, it is possible to manufacture a lightweight buffer mat.

In addition, the cushioning mat of the present invention has sufficient voids between the spherical foam cells integrated through thermal fusion, so that moisture does not fill the inside, and it is excellent in shock absorption ability and elastic restoring force. In addition, since no binder is used, it is eco-friendly, and there is no smell of binder, so it can be used without burden. Since the unit foam cell itself is integrated, it is not easily cracked or torn even after long use.

Furthermore, the cushioning mat of the present invention can be used in a cushioning seat inside a safety helmet in an industrial field, a bicycle or horseback riding saddle, a flooring material in a car, and water lifesaving equipment.

1 is a block diagram illustrating a method of manufacturing a cushioning mat having breathability according to a first embodiment of the present invention.
2 is a view schematically showing a method of manufacturing a buffer mat having air permeability according to a first embodiment of the present invention.
3 is a cross-sectional view separately showing the upper mold shown in FIG.
4 is a perspective view illustrating the lower mold of FIG. 2 .
5 is a view schematically showing a modified example of the method of manufacturing a buffer mat having air permeability according to the first embodiment of the present invention.
6 is a perspective view of the lower mold of FIG. 5 .
7 is a block diagram for explaining a method of manufacturing a cushioning mat having breathability according to a second embodiment of the present invention.
8 is a diagram schematically showing a method of manufacturing a buffer mat having breathability according to a second embodiment of the present invention.
9 is a plan view of the forming roll device of FIG.
FIG. 10 is a perspective view of the intake roller shown in FIG. 8 .
11 is a view showing a buffer mat manufactured through a method for manufacturing a buffer mat having breathability according to a second embodiment of the present invention.

Hereinafter, one embodiment according to the present invention will be described in more detail with reference to the accompanying drawings.

1 is a block diagram for explaining a method of manufacturing a cushioning mat having breathability according to a first embodiment of the present invention, and FIG. 2 is a diagram schematically showing the manufacturing method. In addition, FIG. 3 is a cross-sectional view separately illustrating the upper mold shown in FIG. 2 , and FIG. 4 is a perspective view illustrating the lower mold of FIG. 2 .

As shown, the buffer mat manufacturing method according to this embodiment includes a foam cell preparation step 101, an input step 103, a molding step 105, a shower step 107, and a drying step 109. .

The foam cell preparation step 101 is a process of preparing the foam cell (11 in FIG. 1a), which is a raw material for manufacturing the buffer mat 100. The foam cell 11 is formed by foam molding of a thermoplastic polyurethane material, and has elasticity and takes the form of an amorphous sphere. For example, it can have the shape of a bean. The particle diameter of these foam cells 11 may vary depending on the embodiment, for example, may be 1 cm or less.

Each of the prepared foam cells 11 is independent and does not stick to each other before being used. In addition, the inside of each foam cell 11 includes a micro-hole (11a). The fine hole 11a is a closed space containing air and increases the elasticity of the foam cell 11 . In other words, when the foam cell 11 is pressed, it is elastically deformed and restored to the initial position when the pressing force is removed. This property is due to the action of the micro-holes 11a.

The input step 103 is a process of putting the prepared foam cell 11 into the mold, as shown in FIG. 2B . That is, the foam cell 11 is filled in the molding space 13a of the lower mold 13 opened upward. The mold consists of a lower mold 13 and an upper mold 19 , and the foam cell 11 is pressed and molded by the upper mold 19 while being accommodated in the lower mold 13 .

The upper mold 19 has the configuration shown in FIG. 3 .

As shown in Fig. 3, the upper mold 19 has a mold case 19a and a heater 19d. The mold case 19a provides a heating space 19e, and accommodates the heater 19d in the heating space 19e. The heater 19d heats the air inside the heating space 19e by generating heat by electric power applied from the outside.

In addition, a pressing surface portion 19c is located on the lower side of the mold case 19a. The pressing surface portion 19c serves to press down the foam cell 11 inside the lower mold 13, as shown in FIG. 2c. In addition, a plurality of air supply holes 19b are formed in the pressing surface portion 19c. The air supply hole 19b is a hole through which the air heated by the heater 19d is discharged downward. Of course, the inner diameter of the air supply hole (19b) is smaller than the minimum particle diameter of the foam cell (11).

Reference numeral 19g denotes an air supply port. The air supply port (19g) is a passage to which the air supply pipe (19f) is fixed. The air supply pipe 19f is a pipe that guides external air into the heating space 19e of the upper mold 19 .

As a result, the upper mold 19 serves to press down the foam cell 11 and, at the same time, heat the outside air and then supply it to the foam cell 11 through the air supply hole 19b.

4 shows the lower mold 13 .

As shown, the lower mold 13 provides a molding space 13a open to the upper portion, and has a plurality of exhaust holes 13e in the bottom portion 13b. The molding space 13a is a space for accommodating the foam cell 11 . The exhaust hole 13e is a passage through which the hot air coming down from the upper mold 19 is discharged to the lower part.

In addition, the negative pressure chamber 15 is fixed to the lower side of the lower mold 13 . The negative pressure chamber 15 is a case in which the rim portion is fixed in close contact with the bottom surface of the lower mold 13 and includes an exhaust hole 13e in its inner region. The air that has passed downward through the exhaust hole 13e is collected in the space portion 15a of the negative pressure chamber 15 .

The negative pressure chamber 15 is connected to the exhaust pump 17 through the exhaust pipe 16 . Therefore, when the exhaust pump 17 is operated, a negative pressure is formed in the space portion 15a, and the air inside the molding space 13a is sucked out.

Again, the description will be continued with reference to FIG. 2 . In the molding step 105 following the input step 103, as shown in FIG. 2c, the foam cell 11 injected into the lower mold 13 is pressed to shape the foam cell 11 and heat is applied at the same time, so that the surface of the foam cell is It is a process of melting and fusion bonding with each other.

The molding step 105 includes a pressing process 105a and a ventilation welding process 105b. The pressing process (105a) is a process of lowering the upper mold (19) to press the foam cell (11) downward with the pressing surface portion (19c). Through the pressing process (105a), the foam cell (filled in the molding space (13a)) is pressed downward and has a certain thickness.

In particular, even when the foam cells 11 are pressed, the voids between the foam cells 11 are maintained as they are. The pressing force is adjusted so that the air gap can be maintained. The final thickness of the foam cells after being pressed by the upper mold 19 is 80% to 95% compared to the average thickness of the foam cells before being pressed.

The pressing process (105a) is not intended to increase the density by pressing the foam cells 11, but is to be performed in order to closely contact the foam cells that are adjacent to each other but are spaced apart from each other.

The ventilation welding process (105b) is a process that proceeds simultaneously with the pressing process (105a). That is, while pressing the foam cell 11 with the upper mold 19, the air introduced into the upper mold through the supply pipe 19f is heated using a heater 19d, and then the air supply hole 19b is closed. It is to be discharged to the molding space (13a) through.

The hot air discharged downward through the air supply hole 19b passes through the gaps between the foam cells 11 and melts the surface of the foam cells to make them soggy. Since the foam cells 11 are in contact with each other elastically by the upper mold, the neighboring foam cells 11 are integrated with each other after all. The foam cells 11 that were separated from each other are integrated. Even if the foam cells 11 are integrated, since only a portion of the surface of the foam cells is integrated, it is natural that voids remain between the foam cells 11 .

Next, after the upper mold 19 is raised, the molded product 21 is taken out from the lower mold 13 as shown in FIG. 2D . The molding 21 is a result after completing the molding step 105 .

As shown in Fig. 2e, the molded article 21 takes the form of a plate having a certain thickness, and includes a void 21b therein. The gap 21b is not sealed and is a space open to the outside.

The shower step 107 that follows is a process of cooling the foam cell inside the molding by applying a refrigerant to the molding 21 and allowing the refrigerant to pass through the pores 21b inside the molding, as well as removing heat and foreign substances in the pores. . The refrigerant may be cooled water, that is, cooling water.

That is, as shown in Fig. 2f, the molding 21 is placed on the perforated table 41a of the shower device 41, and the refrigerant is poured downward through the refrigerant supply head 41e so that the refrigerant thickens the molding 21. to pass in that direction. The poured refrigerant passes through the voids 21b by the action of gravity, cools the foam cell and washes away foreign substances in the voids.

The drying step 109 is a process of drying the molding 21 by rotating the drying fan 45a while the molding 21 is placed on the porous table 45b of the drying device 45 . The air descending from the drying fan 45a completely removes moisture inside the air gap 21b.

Through the drying step 109, the buffer mat (100 in FIG. 2H) according to the present embodiment is completed.

5 is a view for explaining a manufacturing method of manufacturing a buffer mat using the upper mold 27 and the lower mold 25 of a structure different from the upper mold 19 and the lower mold 13 shown in FIG. 2, 6 is a perspective view of the lower mold of FIG. 5 .

As shown, the lower mold 25 provides a molding space 25a open to the upper portion and contains a plurality of heaters 25f. The molding space (25a) is a space for accommodating the injected foam cells (11). In addition, the heater 25f heats the lower mold 25 by generating heat by electric power applied from the outside. The foam cell 11 is heated by receiving heat from the lower mold 25 and becomes a damp state.

In addition, a plurality of introduction holes (25e) are provided in the outer portion of the lower mold (25). The introduction hole 25e is a passage for guiding air around the lower mold 25 into the molding space 25a when the exhaust pump 17 is operated.

In addition, four exhaust tubes 25k are installed on the bottom portion 25b of the lower mold 25 . The exhaust tube 25k is a hollow pipe extending perpendicularly to the bottom portion 25b, and has a plurality of intake holes 25m. The intake hole 25m is a hole for sucking air inside the molding space 25a in a state where the upper mold 27 is lowered, as shown in FIG. 5D .

The lower end of the exhaust tube 25k extends to the lower part of the lower mold 25 and then leads to the exhaust pipe 16 . As the exhaust pump 17 operates, the air around the exhaust tube 25k is sucked in and exhausted to the outside.

The upper mold 27 is installed so as to be liftable on the upper part of the lower mold 25 and includes a plurality of heaters 27e therein. The heater 27e generates heat by electric power applied from the outside to heat the upper mold itself. In addition, four tube holes (27c) are formed in the upper mold (27). The tube hole 27c is a space for accommodating the exhaust tube 25k in a state in which the upper mold 27 is lowered.

The buffer mat manufacturing method using the upper mold 27 and the lower mold 25 of the above structure has a pressing process (105a) and a ventilation welding process (105b) different from those described with reference to FIG. 2 .

In the pressing process 105a using the upper and lower molds 27 and 25, the foam cells 11 put into the lower mold 25 are pressed with the upper mold 27, so that adjacent but separated foam cells are in close contact with each other. It is a process that makes

In addition, in the ventilation fusion step 105b, the heaters 27e and 25f are operated to fuse the surfaces of the neighboring foam cells, and at the same time, the exhaust pump 17 is driven to drive the exhaust tube 25k through the molding space. It is the process of extracting the air from the inside.

By operating the exhaust pump 17, the air around the lower mold 25 flows into the molding space 25a through the introduction hole 25e, and the air introduced into the molding space 25a is converted into a foam cell ( 11) is introduced into the exhaust tube 25k through the gap 21b between them and is drawn out. The air passing through the flow path prevents clogging of the pores 21b in the molding 21 during the fusion process (see FIGS. 5c and 5d).

In the molding 21 manufactured through the above process, four through holes 21c are formed. The through hole 21c is a hole through which the exhaust tube 25k is removed.

7 is a block diagram for explaining a method of manufacturing a cushioning mat having air permeability according to a second embodiment of the present invention, and FIG. 8 is a diagram schematically illustrating a method of manufacturing a cushioning mat. 9 is a plan view of the forming roll device 33 shown in FIG. 8, and FIG. 10 is a perspective view of the intake roller shown in FIG. In addition, FIG. 11 is a view showing the buffer mat 100 manufactured by the method of manufacturing a buffer mat having air permeability according to the second embodiment of the present invention.

The buffer mat (100 in FIG. 11) manufactured by the manufacturing method of the second embodiment has a thin structure, unlike the buffer mat in the first embodiment, and can be wound around the bobbin 200 as shown in FIG. . The thickness of the cushioning mat 100 wound around the bobbin 200 is 10mm or less.

Hereinafter, the same reference numerals as the above reference numerals refer to the same members or processes having the same functions.

As shown, the buffer mat manufacturing method according to the second embodiment includes a foam cell preparation step 101, a heating step 111, a molding step 113, a pore securing step 115, a shower step 107, It includes a drying step 109 and a winding step 125 .

The heating step 111 is a process of continuously transferring and heating the foam cell 11 so that the surface of the foam cell is melted and soggy. That is, as shown in FIG. 8, the foam cells 11 continuously supplied through the hopper 29a and the swash plate 29b are placed on the conveyor 29c and transported at a constant speed, installed on the conveyor 29c. It is to melt the surface of the foam cell (11) using the heater (31).

In the subsequent molding step 113, the foamed cells that have completed the heating step 111 are put into the molding roll device 33 so that the foamed cells are compressed while passing through the molding roll device, so that the It is a process of obtaining a continuous sheet-like molding 21 .

The forming roll device 33 includes a pair of rollers 33a, a heater 33g incorporated in the rollers 33a, and a motor 33h for rotating the rollers 33a. The roller 33a is installed on the downstream side of the conveyor 29c, and receives the foam cell 11 falling from the conveyor 29c and compresses it while passing it therebetween. The rollers 33a are spaced apart in parallel to provide a forming space 33c. The molding space 33c is a space through which the foam cell 11 passes. In addition, the heater (33g) heats the roller (33a) to heat the foam cell (11) passing through the molding space (33c) once more.

The air gap securing step 115 is a process of receiving and passing the molding 21 from the molding roll device 33, and passing air in the thickness direction of the molding to secure the voids inside the molding. That is, after passing through the forming roll device 33, heated air is forcibly passed in the thickness direction of the molded article 21, which is transferred and slowly cooled, to secure a gap. If the void securing step 115 is not performed, the void may be narrowed.

In order to perform the air gap securing step 115 , the intake roller 37 , the heated air supply unit 35 , and the exhaust pump 17 are used. The intake roller 37 is a cylindrical member having a predetermined diameter and providing an inner space 37c, and has a hollow shaft 37d at the rotational center shaft portion. In addition, a plurality of intake holes 37b are formed at the periphery of the intake roller 37 . The intake hole (37b) is a hole leading to the inner space (37c) through the surrounding air. The hollow shaft 37d is connected to the exhaust pump 17 through the exhaust pipe 16 . When the exhaust pump 17 operates, the air inside the intake roller 37 is sucked out and the internal space 37c is in a state of negative pressure.

As shown in FIG. 8 , the intake roller 37 supports and supports the molded product 21 and guides the continuous transfer of the molded product 21 .

The heated air supply unit 35 takes in the surrounding air and then heats it and ejects it toward the intake roller 37 . The heated air ejected from the heated air supply unit 35 passes through the voids inside the molding 21 and the intake hole 37b of the intake roller in turn, and then flows into the inner space 37c. As mentioned above, the air in the inner space 37c is discharged to the outside by the exhaust pump 17 .

After completing the step of securing the voids (115), the molding 21, the shower step (107) by the refrigerant supply head (41e), the drying step (109) using the drying device (39), and the winding step (125) It is wound on the winding unit 50 through the. The winding step 125 is a process of winding the continuously produced buffer mat around the bobbin 200 . The winding method itself uses a general technique.

The cushioning mat 100 manufactured by the manufacturing method of the first and second embodiments described above has an excellent cushioning capacity and good breathability because it has a shock absorption capacity provided by the pores in addition to the elasticity of the foam cell 11 itself. Therefore, as mentioned above, it can be used for various purposes other than the interlayer noise mat.

As mentioned above, although the present invention has been described in detail through specific embodiments, the present invention is not limited to the above embodiments, and various modifications are possible by those of ordinary skill within the scope of the technical spirit of the present invention.

11: Foam cell 11a: Micro hole 13: Lower mold
13a: molding space 13b: bottom part 13e: exhaust hole
15: dark chamber 15a: space part 16: exhaust pipe
17: exhaust pump 19: upper mold 19a: mold case
19b: air supply hole 19c: pressing surface part 19d: heater
19e: heating space 19f: air supply pipe 19g: air supply port
21: molding 21b: void 21c: through hole
25: lower mold 25a: molding space 25b: bottom
25e: Inlet hole 25f: Heater 25k: Exhaust tube
25m: intake hole 27: upper mold 27c: tube hole
27e: Heater 29a: Hopper 29b: Slope plate
29c: conveyor 31: heater 33: forming roll device
33a: roller 33c: molding space 33g: heater
33h: motor 35: heating air supply unit 37: intake roller
37b: intake hole 37c: inner space 37d: hollow shaft
39: drying device 41: shower device 41a: perforated table
41e: refrigerant supply head 45: drying device 45a: drying pan
45b: perforated table 50: winding part 100: buffer pad
200: bobbin

Claims (9)

A foam cell preparation step of preparing and preparing in advance independent foam cells separated from each other, which are formed by foam molding of a thermoplastic polyurethane material, have elasticity and take the form of an amorphous sphere;
An input step of putting the prepared foam cells into the mold;
By pressing the foam cells put into the mold, the foam cells are brought into contact with each other, and heat is applied while maintaining the voids, so that the surfaces of the neighboring foam cells are melted by heat and fused to each other. A forming step of producing a;
It includes a drying step of drying the molded product obtained through the molding step,
The mold is a mold of a type capable of ventilation,
The forming step is;
A pressing process of pressing the foam cell to take the form of a plate,
As a process proceeding simultaneously with the pressurization process, it includes a ventilation fusion process in which heated air passes through the gaps between the foam cells, and the adjacent foam cells are fusion-bonded by the heat of the air,
Between the forming step and the drying step,
A shower step of cooling the surface of each foam cell and removing heat and foreign substances in the pores is further included by adding a refrigerant to the molding and allowing the refrigerant to pass through the pores inside the molding,
The drying step;
It is a process in which drying air is blown to the molding after the shower step has been completed, so that the drying air passes through the pores inside the molding and removes the moisture inside the pores.
A method of manufacturing a cushioning mat having breathability. delete delete The method of claim 1,
The mold;
A lower mold that provides a molding space open upward and an exhaust hole is formed in the bottom portion, is provided so as to be able to move up and down on the upper portion of the lower mold, and has an air supply hole for discharging air introduced from the outside downward, the air Including an upper mold with a built-in heater for heating,
The pressurization process;
It is a process of pressing the foam cells put into the molding space of the lower mold with the upper mold to make neighboring but separated foam cells close to each other,
The ventilation fusion process is;
A process in which the air introduced into the upper mold is heated using a heater and then discharged to the lower part through the air supply hole so that the heated air passes through the pores between the foam cells and melts the surface of the foam cells to be fused.
A method of manufacturing a cushioning mat having breathability. The method of claim 1,
The mold;
A lower mold that provides an open forming space to the upper part and has a built-in heater, an inlet hole for guiding outside air into the forming space, and an exhaust tube for discharging the air inside the forming space to the outside, and the upper part of the lower mold can be raised and lowered It is installed so as to include an upper mold with a built-in heater,
The pressurization process;
It is a process of pressing the foam cells put into the lower mold with the upper mold to make neighboring but separated foam cells closely adhere to each other,
The ventilation fusion process is;
It is a process of fusing the surface of the foam cells by operating a heater and at the same time extracting the air from the inside of the molding space through the exhaust tube so that the air is exhausted through the gaps between the foam cells,
A method of manufacturing a cushioning mat having breathability. delete delete Made by the manufacturing method of any one of claims 1, 4, and 5,
buffer mat. delete

Images