KR102465639B1 - assembly type mat molding method - Google Patents

Abstract

The present invention provides an assembly type mat molding method. According to an embodiment of the present invention, an assembly type mat molding method comprises: a raw material preparation step of preparing for molding by storing urethane and hardener, which are raw materials for molding a mat, in respective storage tanks (S110); a raw material heating step of receiving each raw material stored in the storage tank and storing the raw material in a heating tank while heating and stirring the raw material to a molding temperature (S120); a raw material supplying step of transferring the raw materials to a raw material injection apparatus (100) capable of injecting the raw materials into a mat molding apparatus by transferring the urethane and the hardener respectively heated in the raw material heating step (S120) by using a pump and mixing urethane and the hardener (S130); attaching release paper to the molding apparatus so that a product can be easily separated from the molding apparatus after molding the product by attaching the release paper to a lower mold (220) and an upper mold (230) of the molding apparatus (S140); a raw material injection step of injecting the raw material into the molding apparatus to which the release paper is attached by using the raw material injection apparatus (100) (S150); a mat molding step of covering the lower mold (220) and the upper mold (230) and curing the lower mold (220) and the upper mold (230) to mold the product (S160); a burr removal step (S170) of removing burrs remaining on the edge of the molded mat; and a compression step of compressing the upper and lower surfaces of the mat to pressurize the upper and lower surfaces of the mat from which the burrs are removed to make tissue dense and to preserve cushioning feeling (S180). The present invention can minimize a defect rate.

Description

Assembly type mat molding method {assembly type mat molding method}

The present invention relates to a method for forming a prefabricated mat, and more particularly, a method for forming a prefabricated mat that can easily and conveniently manufacture a large amount of prefabricated mats by improving the convenience of production and at the same time minimize the manufacturing defect rate of the mat. It is about.

In general, mats used at home or in various gyms are formed in the form of a flat plate to have a predetermined area and thickness and are configured to have elasticity, and are mainly spread on the floor to prevent noise between floors or to prevent injuries such as infants and children. .

However, since the shape and size of the floor to be laid are diverse, there is a disadvantage that the mat must be folded or cut to a certain size to correspond to the shape of the floor. Accordingly, several mats must be used as a puzzle to respond to the various shapes of the floor. A puzzle-type mat that is assembled and used in a mold has been developed. That is, using a plurality of mat blocks made of a rectangular shape, they are assembled and used according to various shapes of the floor.

Accordingly, the puzzle-type mat is provided with a plurality of puzzle-type mats as in Prior Art Document 1, but the mat is configured to have a plurality of grooves and protrusions along the outer circumferential surface. At this time, the plurality of puzzle-type mats have a structure that can be coupled to each other, and have a plurality of coupling protrusions or coupling grooves so that they can be coupled to each other. That is, a plurality of complementary coupling protrusions or coupling grooves are provided along the outer circumferential surface of the puzzle-type mat so that the plurality of mats can be coupled to each other.

Therefore, a plurality of puzzle-type mats are assembled and used in a shape corresponding to the shape of the floor in a manner of mutual coupling. At this time, as shown in FIG. 1, when the puzzle type mat is combined into the final shape of the floor to be spread, the first mat 10 located at the center and the second mat 20 located at the edge ), and the first mat 10 and the second mat 20 are properly assembled and used.

However, conventional puzzle-type mats are cured by mixing raw materials during manufacture, heating them to a certain temperature, and then injecting them into a mold to form a mat. At this time, a constant temperature must be applied to the raw materials to be cured. Since the shape of the mat, which expands in volume due to the chemical reaction, must be maintained, the upper and lower molds constituting the shape of the product must be cured while completely covering, so the cured product is placed on the upper and lower molds. There was a disadvantage that the product was defective due to hardening while being adhered, and there was a disadvantage that it was inconvenient to remove foreign substances attached to the mold.

In addition, in the case of the existing puzzle-type mats, there is a disadvantage that the operator must directly inject the raw material into the mold, and it is inconvenient to manufacture a large amount of mats.

Therefore, the applicant of the present invention has come to devise a method for forming a prefabricated mat to solve the conventional problems as described above.

Prior Art Document 1: Korean Patent Publication No. 10-2019-0041433 (20190422)

According to one embodiment of the present invention, to provide a method for forming an assembly-type mat that can easily and conveniently manufacture a mat by automatically injecting raw materials into a mold and at the same time preventing the raw material to be cured from adhering to the mold do.

The present invention discloses a method for forming a prefabricated mat. According to one embodiment of the present invention, a raw material preparation step of preparing molding by storing urethane and a curing agent, which are raw materials for molding a mat, in respective storage tanks, and receiving each raw material stored in the storage tank in a heating tank A raw material heating step of heating and stirring the raw material to the molding temperature while storing it, and a raw material capable of injecting the raw material into the mat forming device after transferring the heated urethane and curing agent using a pump, respectively, in the raw material heating step and mixing them The raw material supply step of transferring the raw material to the injection device, and the release paper attaching to the molding device so that the product can be easily separated from the molding device after molding the product by attaching the release paper to the lower and upper molding frames of the molding device, respectively. A raw material injection step of injecting a raw material into the molding device to which the release paper is attached using a raw material injection device, a mat forming step of covering the lower and upper molds and then curing them to form a product, and the molding is completed. Assembled mat comprising a deburring step of removing burrs remaining on the rim of the mat and a compression step of compressing the upper and lower surfaces of the mat to pressurize the upper and lower surfaces of the mat from which the burrs are removed to make the tissue dense and to enhance the cushioning feeling. A molding method is provided.

The assembly-type mat molding method according to the present invention enables the automatic injection of mixed raw materials into a plurality of molding devices using an injection device, so that a mat can be easily and simply manufactured, and a peeling film is installed in a molding frame. The cured mat can be easily separated from the mold, and the defect rate can be minimized, such as the mat not being fused to the mold.

1 is a diagram schematically showing a puzzle-type mat.
2 is a flow chart of a method for forming a prefabricated mat according to an embodiment of the present invention.
3 is a view schematically showing an injection device used in a method for forming a prefabricated mat according to an embodiment of the present invention.
FIG. 4 is a schematic view of the raw material injection unit of FIG. 3 .
5 is a view schematically showing a molding apparatus used in a method for forming a prefabricated mat according to an embodiment of the present invention.
FIG. 6 is a view schematically illustrating a coupling relationship between a hinge unit and a pressurizing unit of FIG. 5 .
FIG. 7 is a view schematically showing the operation of FIG. 6 .
8 is a schematic view of the fastening unit of FIG. 5;

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

Prior to this, the terms or words used in this specification and claims should not be construed as being limited to the usual or dictionary meaning, and the inventor appropriately uses the concept of the term in order to explain his/her invention in the best way. It should be interpreted as a meaning and concept consistent with the technical idea of the present invention based on the principle that it can be defined.

Therefore, the embodiments described in this specification and the configurations shown in the drawings are only one of the most preferred embodiments of the present invention, and do not represent all the technical ideas of the present invention, so at the time of this application, they can be replaced. It should be understood that there may be many equivalents and variations.

Referring to FIG. 2, the assembly type mat molding method according to an embodiment of the present invention includes a raw material preparation step (S110) of preparing molding by storing urethane and a curing agent, which are raw materials for molding a mat, in respective storage tanks; A raw material heating step (S120) of receiving each raw material stored in the storage tank and storing it in a heating tank while heating and stirring the raw material to a molding temperature, and pumping the urethane and curing agent heated in the raw material heating step (S120), respectively A raw material supply step (S130) of transferring the raw material to the raw material injection device 100 capable of injecting the raw material into the mat forming apparatus by mixing it after transferring the raw material, and the lower molding frame 220 and the upper molding of the molding apparatus A release paper attaching step (S140) of attaching the release paper to the molding device so that the product can be easily separated from the molding device after the product is molded by attaching the release paper to the frame 230, and a raw material injection device to the molding device to which the release paper is attached ( 100), a raw material injection step (S150) of injecting raw materials, and a mat forming step (S160) of covering the lower mold 220 and the upper mold 230 and then curing them to form a product, and the molding is completed A burr removal step (S170) of removing burrs remaining on the rim of the mat, and a compression step of compressing the upper and lower surfaces of the mat to pressurize the upper and lower surfaces of the mat from which the burrs are removed to make the tissue dense and to preserve a cushioning feeling. (S180) may be included.

Specifically, the raw material preparation step (S110) is a step of supplying urethane and a curing agent in liquid form, which are the main materials of the mat, to each storage tank and stirring for a certain time, preparing raw materials for molding the mat . That is, since the raw material to be the material of the mat is liquid, the liquid raw material is precipitated when there is no flow for a certain period of time. Therefore, an agitator is installed inside the storage tank to prevent the liquid raw material from precipitating.

Thereafter, each raw material stirred in the storage tank is heated to a suitable temperature for mat molding. That is, the raw material heating step (S120) of stirring each raw material while heating and maintaining it at a temperature suitable for forming a mat by receiving each raw material from the storage tank and heating each raw material in a separate heating tank. do

Thereafter, a raw material supply step is performed so that the raw material heated to an appropriate temperature in the heating tank can be moved to the raw material injection device 100 so that it can be injected into the molding device 200 to be described later. At this time, a stirrer is provided inside the heating tank as in the storage tank so that the stored raw materials can be mixed.

That is, the raw material heated above a certain temperature in the heating tank is moved to the raw material injection device 100 so that it can be injected into the molding device for molding the mat in the heating tank using a pump, and the raw material injection device ( 100) receives and mixes each curing agent and urethane supplied from the heating tank, and then sequentially injects the mixed raw materials into a plurality of molding devices.

Thereafter, a raw material supply step of supplying the raw material to the raw material injection device 100 for injecting each raw material heated and stirred at a constant temperature into the molding apparatus by using a pump is performed.

At this time, as shown in FIG. 3, the raw material injection device 100 includes a support 110 formed to have a predetermined length and a rack gear 112 formed on the upper side along the longitudinal direction, and the support 110 It is coupled to be supported by a plurality of rollers 121 so as to be able to slide along the longitudinal direction, and a pinion gear 122 meshed with the rack gear 112 is provided at the bottom according to the rotation of the pinion gear 122. A movable transfer member 120, a drive motor 130 coupled to the pinion gear 122 to rotate the pinion gear 122 by a power source, and a side surface of the transfer member 120 A fixing bracket 140 fixed to one side and movable along the support 110, and a molding device 200 by mixing urethane and a curing material supplied from the heating tank and fixed to the fixing bracket 140 It may include a raw material injection unit 150 to be injected into.

Here, as shown in FIG. 4, the raw material injection unit 150 is fixedly coupled to the fixing bracket 140 and includes a first support rod 151 through which the urethane in the heating tank is introduced, and the fixing bracket 140 and a second support rod 152 fixedly coupled to allow the curing material in the heating tank to flow in, and connecting the first support rod 151 and the second support rod 152 to each of the support rods 151 and 152. A connection member 153 to mix urethane and hardening material introduced through the connection member 153, and a raw material mixed by the connection member 153 to be injected into the molding device, so that the flow path can be selectively opened and closed It consists of valve 154.

Therefore, in the raw material injection device 100, each raw material in the heating tank is supplied to the raw material injection unit 150 by the pump. At this time, the raw material injection unit 150 is configured to limit the supply of the raw material by the valve 154, and the driving motor 130 is driven while the raw material is being supplied to the raw material injection unit 150. After the transfer member 120 is transferred to the upper side of the molding device 200 located in the desired direction along the support 110, the valve 154 is opened to mix the raw materials in each mold of the molding device 200. can be injected.

On the other hand, when the raw material is supplied to the raw material injection device 100 through the raw material supply step (S130), the release paper attaching step (S140) of attaching the release paper to the molding device 200 for molding the mat is performed.

The release paper attaching step (S140) allows the mat expanded and molded by the chemical reaction of raw materials to be smoothly separated from the molding device 200 when the mat is formed in the molding device 200 later, so that the mat is damaged. It also prevents the raw material from sticking to the molding device 200.

Subsequently, when the above-described release paper attaching step (S140) is completed, a mat forming step (S160) of forming a mat by injecting raw materials into the molding device 200 is performed.

Referring to FIG. 5, the molding device 200 includes a table 210, a lower mold 220 fixed to the table 210 and capable of forming the lower surface of the mat, and the lower mold 220 and the hinge unit 240 are rotatably coupled and coupled to the inner side of the upper mold 230 and the lower mold 220 to mold the upper surface of the mat to shape the mat The forming frame 250 and the hinge unit 240 are pressed so that the upper forming frame 230 can be rotated so that the upper forming frame 230 covers the lower forming frame 220. A pressurizing unit 260 to prevent separation of the upper mold 230 overlapped by the pressurizing unit 260 from the lower mold 220, including a fastening unit 270 can do.

Specifically, the lower mold 220 is fixed to the table 210, and is coupled to one rear side by a hinge unit 240 so that it can be rotated and overlapped with respect to the lower mold 220. At this time, the upper mold 230 and the lower mold 220 each have a heat wire built into the inside so that they are heated to a certain temperature to provide heat when a raw material is injected into the mold.

On the other hand, the hinge unit 240 connecting the lower mold 220 and the upper mold 230 is made of a pair, and the lower connecting member 241 protrudes from one rear side of the lower mold 220 And, an upper connection member 242 protruding from one rear side of the upper mold 230 and having an end rotatably installed by the lower connection member 241 and the hinge pin 243, and the lower connection member (241) a lower auxiliary connecting member 244 positioned to surround both sides and one end rotatably coupled to the lower connecting member 241, and the other end and one end of the lower auxiliary connecting member) 244) rotating shaft 246 It is rotatably coupled through and consists of an upper auxiliary connecting member 245 whose other end is rotatably coupled with the upper connecting member 241.

In addition, the pressing unit 260 is such that the rod is expanded and contracted by power supplied from the outside, and the cylinder is fixed to the table, and the end of the rod is coupled to the rotation shaft 246 of the hinge unit 240 .

Therefore, as the rod is extended with respect to the cylinder by the driving of the pressurization unit 260, as shown in FIGS. 6 and 7, the rotational shaft 246 is pressed, and thus the lower connection member 241 As one end of the lower auxiliary connecting member 244 is lifted upward, the upper auxiliary connecting member 245 rotatably coupled to the lower auxiliary connecting member 244 is rotated, thereby removing the upper connecting member 242. As the upper connecting member 242 is rotated around the hinge pin 243 by pressing, the upper mold 230 can cover the lower mold 220 .

On the other hand, as shown in FIG. 7, the fastening unit 270 fixes the upper mold 230 and the lower mold 220 overlapped by the pressing unit 260 so that they are not separated. ), a fixed support member 271 in which a horizontal protrusion 171a protrudes from one side of the upper surface to which the actuator 271c is rotatably coupled, and a vertical protrusion 271b protrudes from the other side of the upper surface, and the fixed support A "V" shaped rotating piece 272 rotatably installed through the hinge pin of the vertical protrusion 271b of the member 271, and one end rotatably coupled to one end of the rotating piece 272 and the other end A hook 273 provided with a hook 273 that can be fastened to the locking protrusion 230a provided on the upper mold 230, and a hinge pin connecting the fixed support member 271 and the rotating piece 272 Through the pressure piece 274, one end of which is rotatably coupled to one side of the rotation piece 272 and the other end is rotatably coupled to the rod of the actuator 271c, and one end of the pressure pin 276 It may be composed of a fastening support piece 275 that is rotatably coupled to the pressing piece 274 and the other end is rotatably coupled to the hook 273 to rotate the hook 273 and simultaneously press in one direction.

At this time, the hook 273 has a locking jaw formed on one rear side thereof, and when the actuator 271c is driven, the pressing piece 274 and the fastening support piece 275 are rotatably supported. The upper mold 230 ) and the lower mold 220 are prevented from being separated.

That is, when the actuator 271c is driven, the pressure piece 274 is rotated while the rod is extended, and at this time, the pressure pin 276 rotatably coupled to the pressure piece 274 and the fastening support piece 275 ) is rotated, the pressing pin 276 comes into contact with the hook 273 and presses the hook 273, so that the hook is engaged with the hook protrusion 230a provided on the upper mold 230, Separation of the upper mold 230 and the lower mold 220 is prevented.

Therefore, as described above, after attaching the release paper to the lower mold 220 and the upper mold 230, the mold frame 250 to form a mat is seated inside the lower mold 220. In this state, the raw material is injected into the lower mold 220 using the raw material injection device 100, and then the pressurizing unit 260 is driven so that the upper mold 230 covers the lower mold 220 and then fastens. The unit 270 is driven to prevent the lower mold 220 and the upper mold 230 from being separated, thereby forming a mat.

Thereafter, a burr removal step (S170) of removing burrs generated along the edge of the mat formed by the molding device 200 is performed.

The burr removal step (S170) is a burr generated at the part where the upper mold 230 and the lower mold 220 come into contact, that is, the edge portion of the mat during molding in the molding device 200. ), the operator removes the burr using a knife or the like while checking with the naked eye.

Thereafter, a compression step (S180) is performed to press the upper and lower surfaces of the mat from which the burrs are removed using a compression device (not shown) equipped with a pair of pressure rolls to make the tissue dense and to preserve the cushioning feel. Finish the manufacture of the mat.

The assembly-type mat molding method according to the present invention enables the automatic injection of mixed raw materials into a plurality of molding devices 200 using the raw material injection device 100, so that a mat can be easily and conveniently manufactured, and also, a release paper is installed in the molds 220 and 230 so that the hardened mat can be easily separated from the molds, and the defect rate can be minimized such that the mats are not fused to the molds 220 and 230.

In the above, the spirit of the present invention should not be limited to the described embodiments and should not be determined, and it will be said that not only the claims to be described later, but also all modifications equivalent or equivalent to these claims fall within the scope of the present invention. .

S110: raw material preparation step S120: raw material heating step
S130: raw material supply step S140: release paper attachment step
S150: raw material injection step S160: mat forming step
S170: Burr removal step S180: Compression step
100: raw material injection device
110: support 112: rack gear
120: transfer member 121: roller
122: pinion gear 130: drive motor
140: fixed bracket 150: raw material injection unit
151: first support bar 152: second support bar
153: connecting member 154: valve
200: molding device
210: table 220: lower mold
230: upper mold 240: hinge unit
241: lower connection member 242: upper connection member
243: hinge pin 244: lower auxiliary connecting member
245: upper auxiliary connecting member 246: rotating shaft
250: molding frame 260: pressurizing unit
270: fastening unit 271: fixed support member
272: swivel piece 273: hook
274: pressing piece 275: fastening support piece
276: pressing pin

Claims (1)

A raw material preparation step (S110) of storing urethane and a curing agent, which are raw materials for molding the mat, in each storage tank to prepare for molding, receiving each raw material stored in the storage tank and storing it in a heating tank while molding the raw material In the raw material heating step (S120) of heating and stirring to a temperature, and in the raw material heating step (S120), the heated urethane and curing agent are transported using a pump, and then mixed to inject the raw material into the mat molding device 200 In the raw material supply step (S130) of transferring the raw material to the raw material injection device 100, which can be molded after molding the product by attaching the release paper to the lower mold 220 and the upper mold 230 of the molding device 200, respectively Attaching the release paper to the molding device 200 so that the product can be easily separated from the device 200 (S140), and injecting the raw material into the molding device to which the release paper is attached using the raw material injection device 100 A raw material injection step (S150) and a mat forming step (S160) of covering and curing the lower mold 220 and the upper mold 230 to form a product, and the burr remaining on the edge of the molded mat ( A burr removal step (S170) for removing burrs and a compression step (S180) for compressing the upper and lower surfaces of the mat from which the burrs are removed using a pair of pressure rolls, wherein the compression step (S180) includes a pair of press It is made by a compression device equipped with a roll, characterized in that the pair of pressure rolls press the upper and lower surfaces of the mat that has passed through the deburring step (S170),
The molding device 200 includes a table 210, a lower mold 220 fixed to the table 210 and capable of forming the lower surface of the mat, the lower mold 220 and a hinge unit The upper molding frame 230 rotatably coupled by 240 and capable of forming the upper surface of the mat, and the molding frame coupled to the inner side of the lower molding frame 220 to form the shape of the mat 250 and a pressing unit that presses the hinge unit 240 so that the upper mold 230 can be rotated so that the upper mold 230 can cover the lower mold 220 ( 260) and a fastening unit 270 to prevent the upper mold 230 overlapped by the pressing unit 260 from being separated from the lower mold 220,
The hinge unit 240 is composed of a pair, a lower connection member 241 protruding from one rear side of the lower mold 220, and a protruding one from the rear side of the upper mold 230, the end The upper connection member 242 rotatably installed by the lower connection member 241 and the hinge pin 243, and the lower connection member 241 are positioned to surround both side surfaces, and one end of the lower connection member 241 ) and the lower auxiliary connecting member 244 rotatably coupled, and the other end and one end of the lower auxiliary connecting member) 244) are rotatably coupled through the rotational shaft 246, and the other end is rotatably coupled with the upper connecting member 241 It consists of an upper auxiliary connecting member 245 rotatably coupled,
The pressure unit 260 expands and contracts the rod by power supplied from the outside, and the cylinder is fixed to the table 210, and the end of the rod is coupled to the rotation shaft 246 of the hinge unit 240,
The fastening unit 270 is fixedly installed on the table 210, a horizontal protrusion 171a to which the actuator 271c is rotatably coupled protrudes on one side of the upper surface, and a vertical protrusion 271b protrudes on the other side of the upper surface A fixed support member 271, a “V” shaped rotating piece 272 rotatably installed through a hinge pin of the vertical protrusion 271b of the fixed supporting member 271, and the rotating piece 272 A hook 273 having one end rotatably coupled to one end and a hook 273 provided with a hook that can be fastened to the locking protrusion 230a provided on the upper mold 230 at the other end, and the fixing support member 271 A pressing piece 274 having one end rotatably coupled to one side of the rotating piece 272 and the other end rotatably coupled to the rod of the actuator 271c through a hinge pin connecting the rotating piece 272 and , One end is rotatably coupled with the pressing piece 274 through the pressing pin 276 and the other end is rotatably coupled with the hook 273 to rotate the hook 273 and simultaneously pressurize in one direction. It is composed of a support piece 275,
The raw material injection device 100 includes a support 110 having a predetermined length and having a rack gear 112 formed on the upper side along the longitudinal direction, and a plurality of slidably moving along the longitudinal direction of the support 110. Coupled to be supported by two rollers 121, a pinion gear 122 meshed with the rack gear 112 is provided at the bottom to move along with the rotation of the pinion gear 122, and a transfer member 120 , The drive motor 130 coupled with the pinion gear 122 to rotate the pinion gear 122 by power, and fixed to one side of the side of the transfer member 120, the support 110 A fixing bracket 140 that can be moved along the fixing bracket 140, and a raw material injection unit fixed to the fixing bracket 140 and mixing the urethane and the curing material supplied from the heating tank and injecting them into the molding device 200 ( 150),
The raw material injection unit 150 is fixedly coupled to the fixing bracket 140 and is fixedly coupled to the first support bar 151 and the fixing bracket 140 to allow the urethane in the heating tank to flow into the heating tank The second support bar 152, which allows the curing material to flow in, and the first support bar 151 and the second support bar 152 are connected, and the urethane and the curing material flowing through each of the support bars 151 and 152 can be mixed. A prefabricated mat composed of a connecting member 153 and a valve 154 capable of selectively opening and closing the passage by injecting the raw material mixed by the connecting member 153 into the molding device. molding method.

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