KR20130136297A - Functional mat and producing method thereof - Google Patents

Abstract

The present invention provides a mat including a pad of which prevents a functional body from flowing to the outside while performing an utmost effect of the functional body. The present invention includes a lower cover; a pad stacked on the lower cover; a cotton layer stacked on the top of the mat; and an upper cover positioned on the upper side of the cotton layer. The pad includes upper and lower non-woven fabric layers; a powder functional body positioned between the first and second non-woven fabric layers. The upper and lower non-woven fabrics include pores and are connected by a bridge structure. The powder functional body is arranged between the bridge structures. The upper and lower covers, the cotton layer, and the pad are connected by quilting.

Description

Functional Mat and Producing Method

The present invention relates to a pad including a powder-like functional body and a mat comprising the same, and is environmentally friendly, including functional materials such as charcoal and zeolite, and can effectively exhibit the performance of the functional material And a mat comprising the same.

Products such as loess, charcoal, and zeolite are widely known as functional bodies, and many studies have been made on pads containing such functional bodies.

In particular, charcoal is a very beneficial substance such as antibacterial action, deodorizing action, humidity control ability, preservative action, anion emission and far infrared ray emission as well as various diseases treatment effect. Are being researched and manufactured.

However, in such a product, granulation is required to effectively and effectively apply the effect of the functional body to the product. In the case where the granular functional body is embedded in the product, not only the functional body is built in, but also the built- There is a problem that it should not be lost.

Conventionally, there has been proposed a method of applying a granular functional body by pressing with an adhesive or heat, or a structure of inserting a functional body into a closed space and placing the functional body in a product.

However, when the granular functional material is fixed with an adhesive, since the rigidity of the product is increased due to the adhesive, a soft touch can not be obtained. Moreover, since the generally used adhesive is harmful to the human body, There is a problem that the effect of the functional body is deteriorated due to the hazard of the adhesive. On the other hand, in the case of inserting into a closed space, there is a problem that it is difficult to uniformly distribute the functional body, and the effect of the functional body is difficult to manifest due to the material forming the closed space.

Further, in the case of a functional body such as charcoal, the adhesive closes the pores, so that the effect of the char is not exhibited.

Furthermore, when the pad having the functional body is put in the cover and adhered by a method such as a hot press, there is a problem that the functional body is crushed and the cushion feeling disappears and the satisfaction of the user is lowered.

It is an object of the present invention to provide a mat including a pad which does not flow out to the outside while maximizing the effect of the functional body.

Further, it is an object of the present invention to provide a mat, which is easy to process while exhibiting the function of a functional body, and has high user satisfaction, such as a cushion feeling, in manufacturing a mat with a pad including a functional body.

The present invention provides the following mats, and pads and methods for producing the same, in order to achieve the above object.

The present invention relates to a lower cover, A pad laminated on the lower cover; Cotton layer laminated on the upper side of the mat; And an upper cover positioned on the upper side of the cotton layer, the pad comprising: upper and lower non-woven layers; Wherein the upper and lower nonwoven fabrics include pores and are connected to each other in a crosslinked structure, the powdered functional material is disposed between the crosslinked structures, and the upper and lower nonwoven fabrics are disposed between the upper and lower nonwoven fabrics, The cover, the cotton layer and the pad provide a functional mat connected by quilting.

At this time, the powder functional material is a powder char having a particle diameter of 0.5 ~ 1mm, the upper and lower non-woven layer may have a density of 150 ~ 400g / ㎡.

In addition, the upper and lower nonwoven layer may have a density of 150 ~ 250g / ㎡.

In addition, the cotton layer may have a density of 150 ~ 400g / ㎡, one or more of the upper cover and the lower cover may be anionized.

Furthermore, at least one of the upper cover and the lower cover may include a radio wave blocking portion woven with an electric conductive yarn, and the cotton layer may be treated with antibacterial treatment or cathekin.

Alternatively, the present invention provides a method comprising: preparing a lower cover; Disposing a pad on the lower cover; Sequentially arranging a cotton layer and an upper cover on the pad; And peeling the upper and lower covers, the cotton layer and the pad through a needle, the pad comprising: upper and lower nonwoven layers; And a powder functional body positioned between the upper and lower non-woven fabric layers, wherein the upper and lower non-woven fabrics include pores and are connected by a crosslinked structure, and the powder functional body is disposed between the crosslinked structures .

According to the present invention, it is possible to provide a mat having a pad in which the functional body does not flow out to the outside while maximizing the effect of the functional body through the above-described structure.

Furthermore, the present invention can provide a mat having a function of a functional body, a mat having a high degree of user satisfaction such as a cushion feeling while being easy to process, in manufacturing a mat with a pad including a functional body.

1 is an exploded perspective view of a pad including a functional body of the present invention.
Fig. 2 is a cross-sectional view of a pad including the functional body of the present invention. Fig. 2a shows a state before machining, and Fig. 2b shows a state after machining.
3 is an exploded perspective view of the functional mat of the present invention.
4 is a cross-sectional view of the functional mat of the present invention.

Hereinafter, a specific embodiment of the present invention will be described with reference to the accompanying drawings.

Figs. 1 and 2A and 2B show an exploded perspective view of a pad including the functional body of the present invention and a cross-sectional view of the pad including the functional body of the present invention.

The pads including the functional bodies of the present invention are prepared by preparing the upper and lower nonwoven fabrics 10 and 30 having an appropriate size and thickness and forming the powder functional body 20 on the upper surface of the lower nonwoven fabric 30, After the application, the upper nonwoven fabric 10 is placed.

Thereafter, the upper nonwoven fabric 10 is needle-punched through the upper nonwoven fabric 10, the functional body 20, and the lower nonwoven fabric 30 such that the fine fibers of the lower nonwoven fabric 30 are tangled with each other to form a crosslinked structure.

The upper and lower nonwoven fabrics 10 and 30 are formed in a felt shape by arranging the fibers in a parallel or indefinite direction without being subjected to a woven process and bonding them with a synthetic resin adhesive so that the upper and lower nonwoven fabrics 10, The fibers 31 of some of the fibers or portions of the lower nonwoven fabric 30 are entangled with the fibers of the other nonwoven fabric 10 and 30 by the needles N1 so that the upper and lower nonwoven fabrics are formed .

The particles 21 of the powder-like functional body 20 positioned between the upper and lower nonwoven fabrics 10 and 30 at the time of forming the crosslinked structure have a crosslinked structure formed by the fibers 31, As shown in Fig.

On the other hand, in the present invention, the fibers constituting the upper and lower nonwoven fabrics 10 and 30 include all fibers such as synthetic fibers, natural fibers, or combinations thereof, and the amounts of fibers in the upper and lower nonwoven fabrics 10 and 30 are And preferably 150 to 400 g per square meter.

In order to obtain the present invention, according to the results of repeated experiments, when the upper and lower nonwoven fabrics 10 and 30 are each less than 150 g / m 2, due to expansion of the pores by the needle N 1 during needle punching for easy binding or binding, , There is a possibility that the particles 21 of the functional body 20 may leak out through the pores.

In addition, when the upper and lower nonwoven fabrics 10 and 30 are each more than 400 g / m 2, the thickness of the nonwoven fabrics 10 and 30 becomes thicker, thereby lowering the performance of the functional body 20. In the case of various arrangements of the functional body 20, the material cost not only increases, and thus needle punching of the upper and lower nonwoven fabrics 10 and 30 may be difficult. Specifically, when the upper and lower nonwoven fabrics 10 and 30 and the functional body 20 in excess of 400 g / m 2 are disposed and needle punched, there is a problem in that manufacturing becomes difficult due to damage of the needle N1.

The upper and lower nonwoven fabrics 10 and 30 do not need to have the same fiber amount, and they may have different fiber amounts within the range, and their thicknesses are the same.

On the other hand, in the present invention, since the cross-linked structure is formed between the upper and lower nonwoven fabrics 10 and 30 through needle punching and the powdery functional body 20 is located in the cross-linked structure, It is important.

When powder char is used as the functional body 20, the diameter should satisfy the range of 0.5 to 1 mm. In case of charcoal, it is necessary to finely crush the activated carbon to select particles of desired size, and then to clean the fine charcoal powder that has penetrated into the pores, so that unnecessary verification can be prevented.

Also, when the diameter of the char is less than 0.5 mm, it is difficult to fix to the crosslinked structure by the needle punching, so that there is a possibility that the char is brought to the outside of the pad. In addition, since the weight is light, when the needle is sprayed on the lower nonwoven fabric 30 prior to the needle punching, a twisting phenomenon may occur, which may significantly reduce the working environment. In addition, there is a fear that the air is vented to the outside through the vent hole formed by the needle N1.

In addition, when the diameter of the char on the powder is more than 1 mm, it is difficult to avoid the needle N1 in which the powdery char enters the needle punching, which results in the needle N1 being damaged by the char during operation. When the needle N1 is damaged by the charcoal, the work can not be performed and the productivity is deteriorated.

The built-in amount of the charcoal as the functional body 20 is limited to 150 to 600 g per square meter. It is not satisfied that the supplied amount is within a given supply amount, and the squareness of the upper and lower nonwoven fabrics 10, It can be adjusted within the range depending on the amount of sugar per fiber.

For example, when the amount of fibers per square meter of the upper and lower nonwoven fabrics 10 and 30 is 150 g, 150 to 275 g of char is appropriately contained as the functional material 20, and the upper and lower nonwoven fabrics 10, It is preferable that 400 to 600 g of char as the functional body 20 be embedded in the case where the amount of fibers per square meter of the nonwoven fabric 30 is 400 g, So as to sufficiently obtain the effect of the functional body 20.

That is, it is preferable that the built-in amount per square meter of powder charcoal as the functional body 20 is between 1 and 1.5 times the fiber amount per square meter of the upper and lower nonwoven fabrics 10 and 30.

The present invention will be described with reference to Figs. 2A and 2B.

As shown in FIGS. 2A and 2B, the pad 100 including the functional body of the present invention includes a functional body 20 disposed between the upper and lower nonwoven fabrics 10 and 30, And the functional nonwoven fabric 30 is sprayed with the powder of the functional material 20 thereon and then the functional nonwoven fabric 30 is covered with the upper nonwoven fabric 10.

Thereafter, the upper and lower nonwoven fabrics 10, 30 and the functional element 20 are needle-punched at once through the needle N1. At this time, a plurality of the needles N1 may be punched into one set, or may be punched one by one.

The upper and lower nonwoven fabrics 10 and 30 are fixed to the upper and lower nonwoven fabrics 10 and 30 so as to fix the powder of functional material 20 sprayed on the entire upper surface of the lower nonwoven fabric 30, As shown in FIG. As described above, the upper and lower nonwoven fabrics 10 and 30 are formed of the pad 100 including the functional body by joining the functional bodies 20 of the powder through one another through the needle punching.

Particularly, the functional body 20 embedded between the upper and lower nonwoven fabrics 10 and 30 is fixed at a given position by the fibers 31 of the nonwoven fabric 10 and 30 by a needle punching process without being tilted, Since the innumerable pores 11 are formed in the nonwoven fabrics 10 and 30 due to the punching, the antibacterial action, deodorizing action and humidity controlling ability of the functional charcoal 20, in this case powder coals, and antiseptic action, anion release and far- So that the effect of the functional body 20 can be maximized.

Next, a functional mat with a built-in pad 100 including the functional body of the present invention will be described.

Fig. 3 is an exploded perspective view of the functional mat of the present invention, and Fig. 4 is a sectional view of the functional mat of the present invention.

3, a pad 100 including the above-described functional body is disposed on the upper side of the lower cover 130, a cotton layer 120 is disposed on the pad 100, and the upper cover 110 ).

As described above, in the pad 100 including the functional body, the powdery functional body 20 is disposed in the cross-linked structure formed by the fibers 31 between the pores 11 and the nonwoven fabric 10, 30, The effect of the functional body 20 can be expressed over the entire surface of the substrate 100.

However, since the pad 100 is provided on the outer surface of the nonwoven fabric 10, 30, it is difficult to use the pad 100 immediately, and accordingly, the upper and lower covers 110, 130 are required.

However, as mentioned in the related art, when the upper and lower covers 110 and 130 are bonded by heat fusion or the like, not only the pad 100 including the functional body 20 is damaged, .

Accordingly, the inventor of the present invention has studied a functional mat 150 that is easy to use without damaging the pad 100. In this case, the upper and lower covers 110 and 130, (100) and the cotton layer (120).

At this time, the cotton layer 120 plays an important role in the beam. The needle N2 must pass through the upper and lower covers 110 and 130, the pad 100 and the cotton layer 120. At this time, the needle N2 is fixed to the position where the functional body 20 is fixed And passes through the pad 100.

For example, when the functional element 20 is char, the needle N2 must pass through the pad 100 on which the char is fixed. When the char is hit against the needle N2, the needle N2 is damaged , The thread connected to the needle N2 is blown even if the needle N2 passes.

However, in the case of disposing the cotton layer 120 between the upper cover 110 and the pad 100, the needle N2 may be damaged by the buffering effect of the cotton layer 120 even if the pad 100 has a functional material such as charcoal When passing, the damage of the needle N2 and the breakage of the thread can be prevented.

At this time, the cotton layer 120 may be immersed in the green tea and dried to contain the catechin component. By using the cotton layer 120 having the catechin component as described above, the cotton layer 120 enables singulation However, it may also serve to improve the function of the functional body 20.

In this case, it is preferable that the cotton layer 120 has a weight of 150 to 400 g / m < 2 >, but if it is less than 150 g / m2, damage to the needle N2 may occur, / M < 2 >, the effect of the functional body 20 is deteriorated due to the thickness of the batting layer 120 and the density of the cotton layer 120. [

Further, the thickness of the cotton layer 120 is preferably 5 mm or more, and if it is less than 5 mm, there is a problem that the thread attached to the needle N2 is cut off, which makes it difficult to manufacture.

It is preferable that the upper cover 110 and the lower cover 130 are anion-treated to improve the functional effect of the functional body 20. This not only maximizes the performance of the functional mat 150 by generating negative ions in the outer covers 110 and 130 as well as the inner functional bodies 20 but also prevents the inflow of electromagnetic waves, For a longer period of time.

It is also possible to treat only the upper cover 110 with negative ions or only the lower cover 130 with negative ions.

On the other hand, the upper cover 110 that is exposed to the outside may be partly sewn through the electric conductive yarn, or it may be configured to form a radio wave blocking unit 145 by carving a pattern or the like.

In the case of an electric conduction sheet, since electricity is conducted, static electricity absorption and electrostatic shielding as well as electromagnetic wave shielding are possible. This not only keeps performance of the functional body 20 from the outside to maintain its performance, It is possible to improve the effect of the functional mat 150 by providing a difficult function.

A method of manufacturing the functional mat 150 of the present invention will be described with reference to FIG.

As shown in FIG. 4, the pad 100 including the functional unit 20 fabricated in the lower cover 130 is disposed, and the cotton layer 120 is disposed thereon. At this time, the cotton layer preferably has a thickness of 0.5mm or more and a weight of 150 ~ 400g / ㎡.

After the cotton layer 120 is disposed, the upper cover 110 is covered on the cotton layer 120 and the upper cover 110, the cotton layer 120, the pad 100, and the lower cover 130 are fastened to the needle N2.

The upper and lower covers 110 and 130 are coupled to each other while the sealing yarn 140 of the nakamun penetrates the upper and lower covers 110 and 130. The upper and lower covers 110 and 130 as well as the pad 100 including the functional body 20 are coupled with the beam of light so that the performance of the functional body 20 is not affected, 110, and 130 to protect the functional body 20. In addition, by putting various patterns and patterns on the upper and lower covers 110 and 130, aesthetic satisfaction of the user can be provided.

On the other hand, the upper and lower covers 110 and 130 can be supplemented or supplemented with the function of the functional body 20 by previously performing an anion treatment or an electric conduction. Also, the function of the functional layer 20 can be complemented by coating or impregnating the cotton layer 120 with an antimicrobial material such as catechin.

In the present invention, it is preferable that the cotton layer 120 is prepared by a step of filling the cotton water into the green tea water and a step of drying the green cotton water. The cocaine is impregnated through the green tea water, ) In particular, the function of charcoal can be activated.

Example

After the pad 100 shown in FIGS. 1 and 2 was fabricated (using charcoal of 0.5 mm diameter as a functional body), the same pad was placed between the same covers 110 and 130, and the same needle and thread were used Respectively. In Inventive Example 1, the cotton layer 120 was disposed. In Inventive Example 2, the cotton layer was provided, but a thickness of 1 mm was used. In Comparative Example 1, the upper cover 110 and the lower cover 130 were not provided at all. The pad 100 was disposed between the pads.

Table 1 shows the results of unpolymer processing for Inventive Examples 1 and 2 and Comparative Example 1. As shown in Table 1, there was no problem in the single beam processing in the case of the invention example, and in case of the inventive example 2, the yarn was sometimes broken, but there was no problem in the processing. However, in the case of Comparative Example 1, the yarn was almost always broken and it was difficult to perform the beam cutting process.

Function body Diameter of the functional sieve Whether cotton is available Cotton thickness Broken thread Inventory 1 charcoal 0.5 o 5mm Never Inventive Example 2 charcoal 0.5 o 1mm Occasional occurrence Comparative Example 1 charcoal 0.5 x x Frequent occurrence

While the present invention has been particularly shown and described with reference to exemplary embodiments, it is to be understood that the invention is not limited to the disclosed exemplary embodiments, but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.

In the present invention, although charcoal is used as a functional material in the present invention, it is needless to say that it is possible to use a powdery product and a functionally useful product such as zeolite and an antibacterial material.

10: upper nonwoven fabric 11: porcelain
20: Functional body 21: Particle
30: Lower nonwoven fabric 31: Fiber
100: pad 110: upper cover
120: cotton layer 130: lower cover
140: thread 145: electrician
150: Functional Mat

Claims (8)

A lower cover;
A pad laminated on the lower cover;
Cotton layer laminated on the upper side of the mat; And
And an upper cover positioned above the cotton layer.
The pad includes upper and lower nonwoven layers; And a powder functional body positioned between the upper and lower nonwoven layers, wherein the upper and lower nonwoven fabrics include pores and are connected in a crosslinked structure, and the powdered functional body is disposed between the crosslinked structures,
And the upper and lower covers, cotton layers and pads are connected by quilting. The method of claim 1,
The powder functional body is a powder char having a particle diameter of 0.5 ~ 1mm,
The upper and lower nonwoven layers are functional mats, characterized in that having a density of 150 ~ 400g / ㎡ 3. The method of claim 2,
The upper and lower nonwoven layers are functional mats, characterized in that having a density of 150 ~ 250g / ㎡. 3. The method of claim 2,
Functional cotton, characterized in that the cotton layer has a density of 150 ~ 400g / ㎡. 5. The method of claim 4,
Wherein at least one of the upper cover and the lower cover is negatively treated. The method of claim 5, wherein
At least one of the upper cover and the lower cover is a functional mat, characterized in that it comprises a radio wave shield woven with an electric conductor. The method according to claim 6,
Wherein the bedding layer is antibacterial or cadecinized. Steps to prepare the lower cover
Disposing a pad on the lower cover;
Sequentially arranging a cotton layer and an upper cover on the pad; And
Quilting the upper and lower covers, cotton and pads through a needle,
The pad includes upper and lower nonwoven layers; And a powder functional body positioned between the upper and lower nonwoven layers,
The upper and lower non-woven fabric includes pores, are connected in a cross-linked structure, the powder function is disposed between the cross-linked structure functional mat manufacturing method.

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