KR20060089915A - Cushioning material and manufacturing method thereof - Google Patents

Abstract

The present invention relates to a cushioning material having a plurality of cushioning projections having an independent cushioning function and a method of manufacturing the same, and more particularly, a receiving portion having a constant depth, and the receiving portion formed at regular intervals and having a diameter or diagonal length. Polyurethane-based resin, polyvinyl chloride-based resin, polyolefin-based resin, polyvinyl alcohol resin, polystyrene-based resin, NBR latex, SBR latex, phenol-based mold having a cavity having a plurality of grooves of 30 to 120 mm The present invention relates to a cushioning material manufacturing method and a cushioning material produced therefrom, characterized in that the foaming is carried out by injecting a foamed resin which is mixed with one or two or more of resins, melamine-based resins and epoxy resins.

The cushioning method of manufacturing a cushioning material using a mold having a cavity having a receiving portion and a plurality of grooves of a predetermined size, a plurality of cushioning projections integrally formed on the substrate of the manufactured cushioning material independently cushion function By performing pressure or impact on one of the cushioning projections, the shock is not transmitted to the other cushioning projections, and at the same time, air is smoothly communicated between the cushioning projections, thereby producing an optimal sleep atmosphere.

Latex mattress, cavity, mold.

Description

Cushion material and its manufacturing method {CUSHIONING MATERIAL AND MANUFACTURING METHOD THEREOF}

1 is a perspective view schematically showing a mold used in the cushioning method of the present invention.

2A is a longitudinal sectional view schematically showing a longitudinal cross-sectional state of a lower mold in a mold;

Figure 2b is a longitudinal sectional view schematically showing the longitudinal cross-sectional state of the combined upper and lower molds.

3 is a longitudinal sectional view schematically showing a longitudinal cross-sectional state of a mold having a cavity portion formed on an upper mold;

4 is a longitudinal sectional view schematically showing a longitudinal cross-sectional state of a mold in which a cavity portion is formed in both the upper mold and the lower mold;

5A is a perspective view schematically showing a cushioning material manufactured by the mold of FIG. 2B or 3.

5B to 5F are perspective views schematically showing cushioning materials manufactured using respective molds having an octagonal pillar, a cylinder, a truncated cone, a square pillar, and a truncated square pyramid.

Figure 5g is a perspective view schematically showing a cushioning material manufactured using a mold having a different groove size.

5H is a perspective view schematically showing a cushioning material manufactured using a mold having a different shape of a groove;

Figure 6a is a perspective view schematically showing a cushioning material produced by the mold of Figure 4;

Figure 6b is a perspective view showing a cushioning material manufactured using a mold having a groove shape of a truncated square pyramid.

7 is a longitudinal sectional view schematically showing a state in which a heating element is installed in a receiving portion of a cavity portion of a mold;

8 is a plan view schematically showing a planar state of a cushion member on which a heating element is formed.

9A is a plan view schematically showing a unit cushioning material.

9B is a plan view schematically illustrating a state in which a plurality of unit cushioning materials are assembled.

<Description of the symbols for the main parts of the drawings>

10: mold 110: upper mold

130: lower mold 150: cavity (cavity)

152: receiving unit 154: groove

156: pin 70: mold support

20: cushioning material 20a: unit cushioning material

210: substrate 230: cushion projection

310: heating element 330: outlet

350: plug

The present invention relates to a cushioning material having a plurality of cushioning projections having an independent cushioning function and a method of manufacturing the same, and more particularly, a receiving portion having a constant depth, and the receiving portion formed at regular intervals and having a diameter or diagonal length. Polyurethane-based resin, polyvinyl chloride-based resin, polyolefin-based resin, polyvinyl alcohol resin, polystyrene-based resin, NBR latex, SBR latex, phenol-based mold having a cavity having a plurality of grooves of 30 to 120 mm The present invention relates to a cushioning material manufacturing method and a cushioning material produced therefrom, characterized in that the foaming is carried out by injecting a foamed resin which is mixed with one or two or more of resins, melamine-based resins and epoxy resins.

Bedding mattresses that are widely used in the past has been made of a plurality of springs arranged and installed in the inner frame and the palm lock or cushioning material which is superimposed on the spring.

However, the mattress has a structure in which the spring is connected, so when an impact is applied to any part of the mattress, the shock is transmitted as a whole and shakes. Also, as the matless use period becomes longer, metallic friction noise is generated at the connected part of each spring. At the same time, the load on the mattress is not evenly applied to the entire body, but the load is concentrated on the specific area where the hips and chest are in contact with the spine, and the mattress cushion material is buried, making it difficult to restore the original state. There was an inconvenience to use the mattress upside down or turn over time.

In addition, the conventional spring mattress has a problem in that it is easy to scatter harmful elements such as dust or mites, so that special chemical treatment or regular ventilation and aeration are forced.

In order to overcome such problems, the manufacturing method of the mattress using latex, such as domestic registered utility model publication No. 20-0293298, domestic registered utility model publication No. 20-0316278, domestic publication No. 10-2004-0064467 and Techniques for latex mattresses have been suggested.

The Korean Utility Model Utility Publication No. 20-0293298 relates to a latex mattress, comprising: a powdery filler disposed in a latex mattress formed by forming a foamed latex in a predetermined shape so as not to affect the cushioning properties of the foamed latex; Bonding means for bonding the powdery filler to the foamed latex so as not to be separated; And an outer cover surrounding the outside of the foamed latex to which the filler is coupled by the coupling means.

In addition, the filler is characterized in that the charcoal, jade powder, ceramic powder, and the like selectively contained.

However, the registration utility model is to form a plurality of pinholes in the latex mattress in order to improve the breathability in the manufacturing process of the latex mattress, because the powder filler is wrapped in the non-woven fabric inserted into the pinhole, due to structural problems Not only do they fall, but they are not easy to clean. In addition, since the inside of the pinhole is filled with poorly breathable powder, not only the breathability of the latex mattress is significantly reduced, but the cushioning feeling is also degraded.

The domestic registered utility model publication Nos. 20-0316278 and 10-2004-0064467 disclose a functional latex mattress, a latex mattress, and a method for manufacturing the functional latex mattress and a manufacturing apparatus thereof, and a large amount of natural latex mattresses. The technical problem is to provide a production method, apparatus and functional latex mattress that can be produced.

However, the registered utility model and the published patent can only mass-produce a mattress having only a simple pinhole, and still have the problems pointed out in the prior art.

Specifically, since the registered utility model and published patent is a vulcanization mold for vulcanizing the latex stock solution is a rectangular shaped container is formed so that a plurality of pins for forming a pinhole in the latex mattress therein, so as to protrude When a shock is applied to a part, the shock is not absorbed entirely in that part but remains transferred to the other part, eventually shaking the entire mattress, while at the same time the load the mattress receives is not applied evenly throughout the hips. It is still a concern that the burden will be on the spine as the load is concentrated on the specific area where the chest and the like touch.

In order to overcome such problems, a new cushioning material and a manufacturing method thereof are required.

The present invention was created in order to overcome the above problems, a jean catch consisting of a plurality of grooves and pins formed at regular intervals in any one or more of the upper or lower housing of the mold used in the cushion material manufacturing process. It is an object of the present invention to provide a cushioning material and a cushioning material thereby improving the air permeability while at the same time the impact or shock is applied to one portion of the cushioning material is formed by forming a cavity portion.

In addition, by providing a plurality of cushioning projection and the substrate integrally at one time to simplify the production process to improve the productivity and at the same time to provide a cushioning material and a cushioning material thereby significantly reducing the production cost.

In addition, the purpose is to increase the quality effect of the latex mattress by selectively inserting a functional additive and a heating element.

The present invention created to achieve the above object is a cavity (cavity) consisting of a receiving portion having a constant depth, and a plurality of grooves formed at regular intervals and the diameter or diagonal length of 30 to 120mm Polyurethane resin, polyvinyl chloride resin, polyolefin resin, polyvinyl alcohol resin, polystyrene resin, NBR latex, SBR latex, phenol resin, melamine resin, epoxy resin alone It provides a cushioning material manufacturing method characterized in that the foaming by injecting a foamed resin mixed with more than one species.

In addition, the depth of the groove of the cavity portion provides a cushioning material manufacturing method, characterized in that 0.3 to 1.5 times the length of the diameter or diagonal.

In addition, the cavity portion (cavity) provides a cushioning material manufacturing method characterized in that formed in any one or more of the lower mold and the upper mold of the mold.

In addition, it provides a cushioning material manufacturing method, characterized in that a plurality of pins protruding from the cavity (cavity).

In addition, the foamed resin provides a method for producing a cushioning material, characterized in that any one or more substances that exhibit functional properties such as activated carbon, loess, monazite, zeolite, nanosilver, charcoal powder, flavoring, insect repellent, antibacterial agent is mixed.

In addition, after the heating element is installed in the receiving portion of the cavity (cavity) of the mold provides a cushioning material manufacturing method characterized in that the injection molding the injection resin into the mold.

And it provides a cushioning material characterized in that it is produced by any of the cushioning material manufacturing method described above.

Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings. Of course, the scope of the present invention is not limited to the following examples, and various modifications can be made by those skilled in the art without departing from the technical gist of the present invention. .

Cushioning material manufacturing method of the present invention is to prepare a mold having a predetermined cavity (cavity) is formed, injecting a foam resin into the cavity (cavity) of the prepared mold, and then molding the upper mold of the mold with the lower mold and then the appropriate atmosphere After elapse of a certain time within the process such as curing and demolding to produce a cushioning material.

1 is a perspective view schematically showing a mold used in the cushioning material manufacturing method of the present invention. The mold is composed of an upper mold 110, a lower mold 130 and a mold support 170, as shown in Figure 1, the lower mold 130 has a cavity (cavity) corresponding to the shape of the cushioning material to be molded ( 150) is formed.

FIG. 2A is a longitudinal cross-sectional view schematically illustrating a longitudinal cross-sectional state of a lower mold of a mold, and FIG. 2B is a longitudinal cross-sectional view schematically illustrating a longitudinal cross-sectional state of a combined upper mold and a lower mold.

The cavity portion 150 includes a receiving portion 152 having a constant depth, and a plurality of grooves 154 formed at regular intervals in the receiving portion 152 and having a diameter or diagonal length of 30 to 120 mm. The accommodating part 152 is a portion corresponding to the substrate of the cushion material, and the plurality of grooves 154 are portions corresponding to the plurality of cushion protrusions integrally formed on the substrate of the cushion material.

Depth (D1) of the receiving portion 152 depends on the use of the cushioning material to be manufactured, for example, when used on the floor, bed mattress, or the use of the cushion on the chair to make the depth of the receiving portion relatively shallow When manufacturing a cushion material, and if you want to use as a substitute for the cushion of the mattress or chair of the bed, the depth of the accommodating part can be selectively adjusted according to its use, such as manufacturing the cushion material by deepening the depth of the accommodating part. to be. At this time, when the receiving portion of a predetermined depth is formed in the upper mold 110 of the mold as shown in Figure 2b it will be apparent to determine this in consideration of the depth of the receiving portion of the lower mold.

In addition, when the diameter (W) or diagonal length (W) of the plurality of grooves 154 is less than 30 mm, the self-elastic force and the restoring force of the cushion protrusion of the manufactured cushioning material are weak, and thus cannot perform the function of the conventional pocket spring, and also communicate air. There is a problem that does not provide a comfortable and comfortable bed atmosphere to the user because it is not made smoothly, in the case of sitting or lying for a long time in the cushion material to be manufactured for more than 120mm, the contact area with any one of the cushion projection is wide, the air communication to the contact area This is not made smoothly, such as a good night's sleep, such as a lot of sweat is not good, and also has the disadvantage that the appearance is not beautiful.

In addition, the depth D2 of the plurality of grooves 154 is preferably 0.3 to 1.5 times the diameter or the length of the diagonal, which is when the depth D2 of the grooves 154 is less than 0.3 times the length of the diameter or the diagonal Self-elasticity and restoring force of the cushion projection of the cushion material to be manufactured is weak and does not smoothly communicate with the air, in the case of more than 1.5 times, there is a problem that collapsed to one side by the concentrated load applied in any direction.

In addition, although the shape of the groove 154 is shown in hemispherical shape in FIG. 1, the shape of the recess 154 is not limited thereto, and various other three-dimensional shapes such as polygonal pillars such as cylinders, square pillars, and octagonal pillars, truncated cones, triangular pyramids, square pyramids, etc. It can be formed as. In addition, in the case of a truncated cone, a polygonal pyramid may have a flat top but a convex shape. And it may be formed by varying the shape and size of the plurality of grooves. For example, any one groove may be formed in a hemispherical shape having a diameter of 50 mm, and the groove adjacent to the groove may be formed in a hemispherical shape having a diameter of 100 mm to manufacture a cushioning material as shown in FIG. It is also possible to form an octagonal pillar shape, and to form the next two rows of recesses in a cylindrical shape to manufacture a cushioning material as shown in FIG.

Meanwhile, in FIG. 2B, the cavity 150 is formed only in the lower mold 130 of the mold. However, the present invention is not limited thereto, and instead of the lower mold 130 as shown in FIG. The cavity 150 may be formed, and as shown in FIG. 4, the cavity 150 may be formed in both the upper mold 110 and the lower mold 130. Whether or not to form a cavity portion in the cavity can be arbitrarily selected by the manufacturer to suit the purpose.

In addition, a plurality of pins 156 may be further provided in the cavity 150 of the mold as shown in FIG. 1. When the cushion member is manufactured by using the mold having a cavity having the plurality of pins 156, a pinhole (590 of FIG. 5A) is formed in the cushion member, thereby providing excellent elasticity and restoring force. There is an advantage of excellent heat retention.

Next, the foaming resin is injected into the cavity 150 of the mold formed as described above. The foamed resin is one or two or more of polyurethane resin, polyvinyl chloride resin, polyolefin resin, polyvinyl alcohol resin, polystyrene resin, NBR latex, SBR latex, phenolic resin, melamine resin, epoxy resin The foamed resin which mixed this can be used.

In the case of NBR latex and SBR latex, a crosslinking accelerator, a crosslinking agent, a curing agent, a curing accelerator, an oxidizing agent, an anti-aging agent, a filler, and a plurality of additives are mixed with the aged latex stock solution, and then the foam is foamed for a predetermined time. The mixture thus formed is injected into the cavity 150 of the mold and the upper mold of the mold is combined with the lower mold.

However, when air is generated during foaming such as polyurethane-based resin, the mold should further include an air vent hole (not shown) for discharging air to the outside.

In order to use the foamed resin according to its use, it is optionally used by mixing any one or more substances that exhibit functionalities such as activated carbon, loess, monazite, zeolite, nanosilver, charcoal powder, fragrance, insect repellent, and antibacterial agent. It is preferable to, and by providing functionality to the cushioning material manufactured using such a functional material can meet the desire of modern people to live life in a better environment.

In this way, the foamed resin is injected into the cavity 150 of the mold and then molded and then molded through a curing or vulcanization process for a predetermined time, and then demolded with a cushion material having a plurality of cushioning protrusions formed on the substrate.

5A is a perspective view schematically illustrating the cushioning material 20 manufactured by the mold of FIG. 2B or FIG. 3, and FIGS. 5B to 5F are grooves each having an octagonal pillar, a cylinder, a truncated cone, a square pillar, and a truncated square pyramid. Is a perspective view schematically showing the cushioning material 20 manufactured by using a mold. 5G is a perspective view schematically showing a cushioning material manufactured using a mold having different groove sizes, and FIG. 5H is a perspective view schematically showing a cushioning material manufactured using a mold having different groove shapes.

6A is a perspective view schematically illustrating the cushioning material 20 manufactured by the mold of FIG. 4, and FIG. 6B is a perspective view illustrating the cushioning material 20 manufactured by using a mold having a recessed quadrangular pyramid.

5A to F, and FIGS. 6A and 6B, reference numeral 210 is a substrate, 230 is a cushion protrusion, and 250 is a pinhole.

The cushion material 20 having a plurality of cushion protrusions 230 formed thereon capable of performing independent cushioning functions on the substrate 210 manufactured as described above may not only maximize productivity due to a simple manufacturing process unlike conventional pocket springs and the like. There is no need for a separate assembly process, which greatly reduces the production cost. In addition, by further providing the pin 156 in the mold, it is possible to further enhance the cushioning function and the warmth.

Meanwhile, the foaming resin may be injected after the heating element is installed in the accommodation portion of the cavity of the mold. FIG. 7 is a longitudinal cross-sectional view schematically illustrating a state in which a heating element 310 is installed in a receiving portion of a cavity 150 of a mold.

8 is a plan view schematically illustrating a planar state of the cushioning material 20 in which the heating element 310 is formed.

In addition, the heating element 310 may generally use a heating wire that is widely used, but is not limited thereto, and may also use other heating wires such as a silicone heating wire coated with a silicon material and a carbon heating wire formed by coating carbon. In addition, an outlet 330 to which the power supply of the power supply unit is supplied is connected to the heating wire.

However, the arrangement of the heating element 310 is not limited to the arrangement shown in FIG. 8.

On the other hand, when manufacturing a cushioning material used for the general mattress may be formed to correspond to the size of the cavity (cavity) part of the overall size of the mattress for the bed, as shown in Figure 9a easy to produce and distribution process In order to perform effectively and effectively, the unit cushioning material 20a may be manufactured by dividing the total size into two or more parts. The unit cushion member is preferably provided with a plug 330 and an outlet 350, respectively, in order to transmit power to the adjacent cushion member.

9B is a plan view schematically illustrating a state in which a plurality of unit cushion materials 20a are assembled. Thus, when using a single cushion using a plurality of unit cushions, there is an advantage that it is easy to store and transport and to prevent the heating element 310 is damaged during storage and transport.

However, when using as a latex mattress 20 using a plurality of cushioning material (20a) as described above, the wiring of the heating wire of the heating element and the coupling position of the outlet and the plug is limited to those shown in Figs. 9a and 9b. It is not clear.

The present invention has been made to overcome the above problems, by manufacturing a cushioning material using a mold having a cavity (cavity) consisting of a receiving portion and a plurality of grooves of a predetermined size, integrally to the substrate of the manufactured cushioning material The formed plurality of cushioning protrusions independently perform cushioning function so that even if pressure or impact is applied to one of the cushioning protrusions, the shock is not transmitted to the other cushioning protrusions, and at the same time, air is smoothly communicated between the cushioning protrusions to produce an optimal sleeping atmosphere. It has an effect.

And by forming the depth of the groove of the cavity portion 0.3 to 1.5 times the diameter or diagonal length, the plurality of cushion projections of the manufactured cushioning material performs an independent cushion function and is not easily collapsed by external forces such as concentrated load in a certain direction There is.

In addition, by using the mold to form a plurality of cushioning projections and the substrate integrally at a time, the production process is simplified to improve the productivity and at the same time has the effect of significantly reducing the production cost.

And, by mixing any one or more functional materials such as activated carbon, loess, monazite, zeolite, nano silver, charcoal powder, fragrance, insect repellent, antibacterial agent in the foamed resin and injecting into the mold to produce a cushioning material, depending on the intended use There is an effect that can produce a cushioning material that can exhibit a beneficial function to the human body.

In addition, by installing a heating element in the cavity (cavity) of the mold and injecting foamed resin to manufacture a cushioning material, it is possible to provide a warm bed atmosphere to the user in winter, so that a separate mat and cushion with a built-in heating element There is an effect that does not need to be provided.

It is to be understood that the invention is not limited to that described above and illustrated in the drawings and that many more modifications and variations are possible within the scope of the following claims.

Claims (7)

Polyurethane-based resin and polyvinyl chloride-based resin in a mold having a cavity having a predetermined depth and a cavity formed of a plurality of grooves formed at regular intervals and having a diameter or diagonal length of 30 to 120 mm Foaming molding by injecting a foamed resin mixed with one or two or more of resin, polyolefin resin, polyvinyl alcohol resin, polystyrene resin, NBR latex, SBR latex, phenolic resin, melamine resin and epoxy resin Cushion material manufacturing method characterized in that. The method of claim 1, wherein the depth of the groove of the cavity portion is 0.3 to 1.5 times the diameter or the length of the diagonal. The method of claim 1, wherein the cavity is formed in at least one of a lower mold and an upper mold of the mold. The method of manufacturing a cushioning material according to claim 1, wherein a plurality of pins protrude from the cavity portion. [Claim 2] The method of claim 1, wherein the foamed resin is mixed with one or more substances exhibiting functionalities such as activated carbon, loess, monazite, zeolite, nanosilver, charcoal powder, flavoring agent, insect repellent, and antibacterial agent. The method of manufacturing a cushioning material as claimed in claim 1, wherein the foaming resin is injected into the mold after the heating element is installed in the receiving portion of the cavity of the mold. A cushioning material produced by the method according to any one of claims 1 to 5.

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