KR20180071153A - Cushion mat molding device for uniformizing edge adhesion - Google Patents

Abstract

The present invention is a technology associated with a mold device for uniformizing and reinforcing adhesion quality of a cushion mat. The purpose of the present invention is to provide a new mold device technology for improving adhesion quality of edges of the cushion mat, improving manufacturing efficiency per unit hour, improving adhesive force at a bending point on a lower end portion of the cushion mat, and improving operation efficiency such as trimming or the like. A cushion mat mold device of the present invention includes: a first mold supporting a first member; a second mold supporting a second member; a first heating unit inserted between the first and second molds to heat the first and second members; and a mold control unit vertically pressing the first and second molds to fuse the first and second members. The mold control unit is interlocked with the molds and the first heating unit to control the same, thereby fusing the first and second members, and the first heating unit is discharged to the outside of the first and second molds after applying heat to the first and second members. As a result, adhesion quality of the edges of the cushion mat is uniformized, particularly regardless of weather, location and the like, through structure and sequential operation of a new heating plate. Further, the manufacturing efficiency per unit hour is greatly improved, and adhesive quality at the bending point on the lower end portion of the cushion mat is improved.

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention [0001] The present invention relates to a cushion mat mold apparatus,

The present invention relates to a mold apparatus for uniformizing and enhancing the bonding quality of a cushion mat, and in particular, a technique for homogenizing the fusion of edges.

The necessity of the cushion mat installed inside the room is secured as a means for securing safety in children's play or mitigating interlayer noise. Especially, an environmentally friendly manufacturing method which does not use a chemical adhesive is preferred due to the characteristics of the user. Examples include polyethylene foamed forms. The environmentally friendly cushion mat is manufactured by a method of wrapping an inner filling material (first member), which is a cushioning function, with outer sheet material (second member) at upper and lower and left and right outer sides and fusing with heat or high frequency. That is, the first member and the second member are heated by the heating unit, and then thermally fused in a form of being pressed inside the mold made of the upper plate and the lower plate, so that the shape and properties of the certain cushion mat are made.

Recently, the applicant of the present application filed a " method for manufacturing a foldable mat and a system for performing the same ", adsorbing the first member and the second member on a mold of a top plate and a bottom plate by a vacuum adsorption method, And heating the vacuum-adsorbed member, transferring the heating unit to the outside, and then fusing the upper plate and the lower plate.

The present invention is an invention to disclose a new concept related to the transfer of the heating unit in the above-described configuration. That is, when the upper plate, the lower plate, and the heating unit are operated by the automation function, productivity and quality deteriorate easily due to the following phenomenon, and the present invention is intended to solve this problem.

1) Normally, it takes about 5 seconds for the heating part to be transported to the outside by the sliding operation, and the second member, especially the edge (including the frame and the edge) already heated during this period is used. ) Portion of the cushion mat, which causes uneven fusion of the edge portion as viewed from the whole cushion mat square. Even if we increase the heating temperature by a certain temperature considering the time delay for sliding, the quality level changes in morning and afternoon in terms of precision even during the day when the difference of seasons, especially the difference of atmospheric temperature inside the factory due to a rush. Particularly, since the temperature difference occurs between the position where the heating part exits and the position where the heating part is pushed in for transferring, the quality of the mat edge fusion force on the opposite side where the heating part is located is different in quality by the temperature difference. This phenomenon can be exacerbated when the ambient temperature, such as winter, is lowered.

2) When the heating part is formed as a flat plate and it is inserted and removed by sliding, the time for inserting and removing by the sliding operation is a factor that lowers the manufacturing yield. This decrease in yield is more significant when the area of the cushion mat to be produced is larger. If the area is large, the time required until the transport is completed becomes longer. For example, if it takes 5 seconds to insert and 5 seconds to remove, the unit yield will be a loss by 10 seconds of the time, and the larger the size of the mat, the longer the loss time.

   Therefore, in order to improve the deficiencies of the above 1) and 2), there is a need for a technical means for allowing the heated member to be immediately removed while quickly removing the heating unit so that the heated member does not have a margin, or to maintain the heated temperature for a predetermined period. The conception of the present invention includes solutions of these two concepts, thereby improving manufacturing yield per unit time.

3) If the same operation is done for a long time through automation equipment, there is a possibility of deformation in the basic structure of the mold equipment. This is due to changes in atmospheric temperature or the weight and impact applied to the base of the surface from the mold equipment, and this effect can cause problems especially at edge areas where the thickness must be evenly welded to the square surface with a precise thickness. However, it is a difficult problem to make the thickness of the soft material uniform depending on the pressure, and it is necessary to study a new technique for this.

4) In addition, when the multi-end folding type cushion mat is manufactured by fusion welding and then the folded portion is trimmed, a non-contact welded insufficient portion may be generated as described later. In order to solve this problem, not only vertical pressing to the upper and lower molds, It is necessary to perform the horizontal compression using the above-mentioned method. Furthermore, the present invention also includes a technique for simplifying the operation of trimming by using a separate tool through the side plate mold.

1) Korean Patent Application No. 10-2015-0180132 (Dec. 16, 2015); METHOD FOR MANUFACTURING FOLDING MAT AND METHOD OF MANUFACTURING THE SAME 2) Korean Patent Application No. 10-2015-0181909 (Dec. 18, 2015); Cushion mat manufacturing apparatus, manufacturing method and cushion mat manufactured by the same 3) Korean Patent Application No. 10-2016-0012685 (Feb. Safety mold cushion mat and mold for manufacturing this safety cushion mat 4) Korean Patent Application No. 10-2016-0062047 (May 20, 2016); Fusion mold for matting using gravity

It is an object of the present invention to provide a new mold apparatus technology which improves the bonding quality of the cushion mat edge portion, improves the manufacturing efficiency per unit time, improves the adhesion at the lower end bending point of the cushion mat, and improves the work efficiency such as trimming. It is in the cage.

A cushion mat mold apparatus according to an embodiment of the present invention includes: a first mold supporting a first member; A second mold supporting the second member; A first heating unit inserted between the first mold and the second mold to heat the first member and the second member; And a mold control unit for vertically compressing the first mold and the second mold to fuse the first member and the second member. Here, the mold control unit controls the molds and the first heating unit by interlocking to fuse the first member and the second member, and the first heating unit applies heat to the first member and the second member And is discharged to the outside of the first mold and the second mold.

A cushion mat mold apparatus according to another embodiment of the present invention includes: a first mold supporting a first member; A second mold supporting the second member; A first heating unit positioned between the first mold and the second mold to heat the first member and the second member; And a second heating unit for heating an edge portion of the first member or the second member. Here, the first member and the second member are fused after being heated by the heating portions.

A cushion mat mold apparatus according to another embodiment of the present invention includes: a first mold supporting a first member; A second mold supporting the second member; And a first heating part inserted between the first mold and the second mold to heat the first member and the second member and to be separated and combined with the plurality of members. Here, the members of the first heating portion are inserted and joined in at least two directions at the time of insertion into the first member and the second member, and are separated from the first members and the second member, And the first member and the second member are fused after the members are discharged to the outside.

A method of manufacturing a cushion mat according to an embodiment of the present invention includes: supporting a first member and a second member on a first mold and a second mold, respectively; Heating the first member and the second member by placing a first heating unit between the first mold and the second mold; Discharging the first heating unit to the outside of the first mold and the second mold after the heating; Pressing the first mold and the second mold to fuse the first member and the second member; And returning the first mold and the second mold.

According to the present invention, the quality of the edge bonding of the cushion mat is made uniform through the structure of the new heating plate and the sequential operation, irrespective of the weather and the location. In addition, the production efficiency per unit time is greatly improved, and the bonding quality at the lower end bending point is improved.

BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a perspective view and a cross-sectional view showing a member put into the manufacture of a cushion mat and a state after fusion-bonded manufacturing in a vertical direction; Fig.
FIG. 2 is a conceptual illustration of a cushion mat folded in multiple stages and a photograph illustrating an actual process of an experimental process. FIG.
Fig. 3 is a view for sequentially illustrating the principle of folding the cushion mat of Fig. 2 into multiple stages. Fig.
FIG. 4A is a perspective view and a sectional view structurally showing a top mold, a bottom mold and a first heating unit for fusion-molding the multi-stage cushion mat of FIGS. 2 and 3; FIG.
4B is a perspective view and a cross-sectional view illustrating the principle in which the first heating unit is removed to the outside and the upper mold and the lower mold are coupled through the inner space in FIG. 4A.
5A and 5B are a perspective view and a cross-sectional view showing a first embodiment of the present invention in which a second heating part is mounted on a rim surface of a lower mold and controlled.
6A, 6B and 6C are a perspective view and a sectional view showing a second embodiment of the present invention;
FIG. 7A is a photograph and an illustration showing a case where the quality of fusion is uneven in the line-cut surface for folding the cushion mat at multiple stages with only the upper mold and the lower mold.
FIGS. 7B and 7C are cross-sectional views illustrating a third embodiment of a side plate mold for solving the problem shown in FIG. 7A. FIG.
7D is a block diagram for explaining solenoid control, which is an example of the configuration of the side plate mold, with an electric circuit function.
Fig. 7E is a sectional view showing the principle of controlling the posture of a mold in the present invention. Fig.
FIG. 8 is a methodatic flowchart of a first embodiment of the present invention, illustrating a principle of manufacturing a cushion mat through the mold apparatus exemplified in FIG. 5 and FIGS. 7A, 7B, 7C,
Fig. 9 is a methodatic flowchart of a second embodiment of the present invention, which illustrates the principle of manufacturing the cushion mat through the mold apparatus illustrated as Figs. 6a, 6b, 6c and 7a, 7b, 7c,

BRIEF DESCRIPTION OF THE DRAWINGS The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. It is to be understood, however, that the present invention covers all modifications, equivalents, and alternatives falling within the spirit and scope of the present invention, since the present invention is not intended to be limited to the specific embodiments. Although similar reference numerals are used for similar components in describing each drawing, it will be understood that, for example, the terms first, second, etc. are used only for the purpose of distinguishing one component from another, Should not be construed as being limited to the first, second, etc. terms. The terms may be referred to as a second component without departing from the scope of the present invention, and on the same principle, the second component may also be referred to as a first component.

In particular, when the first component and the second component are separately described in the detailed description and only the first component is described in the independent claim and the second component is additionally described in the dependent claim, Is interpreted in the sense that it is meaningless and the 'component' attached to it after it merely serves its function, and when the second component is combined with the relevant dependent claim, it is regarded as a discriminative designation of 'first' and 'second' It should be interpreted as meaning.

Embodiments of the present invention will now be described in detail with reference to the accompanying drawings. The objects and features of the present invention will become more apparent from the detailed description.

First, before explaining the mold apparatus of the present invention, the structure of the cushion mat to be manufactured through the mold apparatus will be described. FIG. 1 is a perspective view and a cross-sectional view showing a member put into the manufacture of the cushion mat and a state after manufacturing the fused cushion mat in the vertical direction.

That is, (a1) and (b1) in FIG. 1 are cross-sectional views of a state in which individual members are inserted, (a2) and (b2) are perspective views of the welded upper and lower surfaces, And (b3) are cross-sectional views of the welded state. (b1, b2, b3) are reversed. In the present invention, the edge portions 31 of the second member 30 are flatly formed on the basis of (b3) The opposite side 10 will be referred to as a bottom portion and the following description will be given.

That is, in FIG. 1, (10) and (30) are fused with the inner filler 20 wrapped around as an outer sheet member. (11) or (31) is an edge portion which is a rim portion after fusion bonding.

FIG. 2 is a photograph conceptually showing a cushion mat folded in multiple stages and illustrating an actual example of an experimental procedure. 2 (a), (b) and (b) of FIG. 2 (a) and 32 (b) show broken lines which are folded backward when the cushion mat is folded in multiple stages. This part is shown as (12) and (32) respectively in (c) real photographs. In Fig. 2, (40) is a corner portion.

FIG. 3 is a view for sequentially illustrating the principle of folding the cushion mat of FIG. 2 into multiple stages. In FIG. 3, (a), (b), (c) . That is, the upper surface portion 30 and the lower surface portion 10 of the cushion mat are finally superimposed as shown in the cross-sectional view of (d), and the directions of breaking are different from each other, . 7A, which will be described later, the upper and lower simple fusion is insufficient, and in order to complete the fusion, it is necessary to weld the corner portion 40, which is a part of the edge portion, It should be done.

Hereinafter, the mold structure of the present invention for forming the above-described cushion mat will be described.

4A is a perspective view and a cross-sectional view of the upper mold metal a1, the lower mold metal a3, and the first heating unit a2 for structural fusion of the multistage cushion mat of Figs. 2 and 3, 4A is a perspective view and a cross-sectional view showing the operation principle in which the upper heating mold a2 is removed to the outside and the upper mold and the lower mold are coupled through the inner space.

That is, in the mold apparatus of the present invention,

An upper plate (100) and a lower plate (300) configured to accommodate a first member as an inner filler and to fuse the first member with a second member as an outer sheet member;

A first heating unit 200 horizontally inserted into the vertical space of the upper plate 100 and the lower plate 300 by sliding so as to heat the respective members and return to the home position after heating is completed;

A mold control unit 700 for vertically pressing the upper plate 100 and the lower plate 300 to fuse the respective members;

The mold control unit controls the upper plate 100, the lower plate 300, and the first heating unit 200 to be interlocked and fusing the respective members.

In the drawing, (b1), (b2) and (b3) show cross-sectional views corresponding to (a1), (a2) and (a3), respectively.

In operation, the first mold apparatus includes:

The upper plate mold 100 and the lower plate mold 300 adsorb the first outer sheet member 10 and the inner filler 20 in a vacuum adsorption manner and are heated to a first heating The first outer sheet member 10 and the inner filler 20 can be heated by inserting the part 200 horizontally.

According to one embodiment, the first heating unit 200 dissipates the first outer sheet member 10 by outputting a far-infrared ray having a high heat penetration capability with the first outer sheet member 10, And can output the low general infrared (IR) to melt the internal filler 20. In this case, only the surface of the inner filler 20 is melted, while the first outer sheet member 10 melts not only the surface but also some inner surface. As a result, the adhesive force between the first outer sheet member 10 and the inner filler 20 becomes strong, and as a result, it becomes considerably advantageous to manufacture a large mat.

The first heating part 200 is horizontally moved to the outside and the first external sheet member 10 and the internal filler 20 adhere to each other to form a structure.

Then, adhesion between the structure and the second outer sheet member 30 is performed. Such adhesion may be achieved by the first mold apparatus or by the second mold apparatus. For the sake of convenience of explanation, it is assumed that the same mold apparatus is used, but each process can be actually performed by different mold apparatuses.

The upper mold 100 and the lower mold 300 absorb the respective structures and the second outer sheet member 30 by vacuum suction so that the first heating unit 200 is horizontally disposed between the upper plate 100 and the lower plate 308, So that the structure and the second outer sheet member 30 can be heated.

According to one embodiment, the first heating unit 200 outputs the far-infrared ray having high heat penetration capability to the second external sheet member 30 to melt the second external sheet member 30, and the internal filler 20, It is possible to melt the internal filler 20 by outputting a general infrared ray (IR) having a low thermal penetration capability. In this case, only the surface of the inner filler 20 is melted, while the second outer sheet member 30 melts not only the surface but also some inner surface. As a result, the adhesion between the second outer sheet member 30 and the structure becomes strong.

On the other hand, the first heating unit 200 may be configured to simultaneously heat the sheet member 10 or 30 and the internal filler 20, or may be sequentially heated. The first heating portion 200 may separately or additionally heat the edge of the inner filler 20. [

The essential point in the basic structure of the present invention is that the first heating portion 200 is slid between the vertical plate upper mold 100 and the lower plate mold 300 to heat the rear member horizontally inserted (a2 in FIG. 4A) The upper mold 100 or the lower mold 300 is vertically moved to the removed space (refer to a4 in FIG. 4B), as shown in FIG. 4B.

In the above structure, the mold control unit 700 will be described in detail in the following specific embodiments.

Reference numeral 101 denotes a rim portion for pressing an edge portion of the upper mold 100 and 102 denotes a partition portion for forming the rupture 32. [ Reference numeral 301 denotes a rim portion for pressing the edge portion of the lower mold 300 and 302 denotes a partition portion for forming the rupture 12.

Particularly, the partition walls 102 and 302 formed in the upper mold 100 and the lower mold 300 are components for vertically cutting the second member (outer sheet member) to form a curved surface of the cushion mat. Since the partition wall is for fusing the sheet member by fusing the sheet member between the outer sheet member and the inner filler, it is preferable that the outer sheet members 10 and 30 are formed in a space in which the outer sheet members 10 and 30 are to be fused and contacted, As shown in FIG.

5A and 5B are a perspective view and a cross-sectional view, respectively, of the first embodiment of the present invention showing an example in which the second heating portion is mounted on the rim surface of the lower mold 300. As shown in Figs. 4A and 4B, Is added.

That is, according to the first embodiment of the present invention,

An upper plate mold 100 and a lower plate mold 300 configured to house a first member as an inner filler and to fuse the first member with a second member that is an outer sheet member;

A first heating unit 200 horizontally inserted into the gap between the upper mold 100 and the lower mold 300 to heat the respective members and return to the home position after the heating is completed;

A second heating part (400) configured to supplementally heat the edge portion temperature of the first member and the second member;

A mold controller 700 for vertically compressing the upper mold 100 and the lower mold 300 while the first heating unit 200 and the second heating unit 400 heat each member and fusing the respective members;

Wherein the mold control unit controls the first heating unit 200 and the second heating unit 400 by interlocking the molds 100 and 300 and fusing the respective members. .

4a and 4b, the description of the operation of the upper mold 100, the lower mold 300, and the first heating unit 200 will be omitted. In the remaining second heating unit 400, And the mold control unit 700 will be described.

*

The second heating unit 400 in the first embodiment compensates for the temperature loss during the period when the first heating unit 200 completes the heating and is removed to the outside through the sliding as a first operation. For this, the second heating unit 400 may be configured as a heating coil 400 surrounding the edge 301 of the lower mold 300. The second heating unit 400 includes a configuration that operates in conjunction with the second heating unit control unit 750.

5B, the second heating unit control unit 750 controls each of the heating coils 400 independent of the four directions in accordance with the temperature change sensed as the sensor unit 752 by the CPU 753, And maintains all of them at a constant temperature. The setting of the control of the heating coil can be performed through the monitor unit and the operating unit 751. The second heating unit control unit 750 can operate each heating coil independently provided as a plurality of output ports.

The heating coils may have one integrated connection configuration, but more preferably at least two independent control configurations are preferred because:

4B, when the first heating part 200 is removed to the outside, the ambient temperature at the lower part of the first heating part (near the left side in FIG. 4B) rises, so that the rim temperature near the first heating part gradually falls. On the other hand, The frame temperature is rapidly lowered. Therefore, if the heating coil 400 of the present invention and the second heating unit control means 750 for controlling the operation thereof independently control the temperature in at least two directions, preferably four directions, a uniform temperature environment can be created as a whole It is.

However, if the temperature difference inside the factory is not serious, it is also possible to arrange only one heating coil to control the temperature to the lower side.

5A, the mold control unit 700 controls the timing at which the second heating unit 400 is operated while operating the upper mold 100 and the lower mold 300. The upper mold 100 and the lower mold 300, And an electric switching function for controlling the second heating unit 400. [0050] Regarding the roles of the mold control unit 700 and the second heating unit control unit 750, when the mold control unit 7000 instructs the operation of the second heating unit 400 (i.e., turns on) The secondary control means 750 performs detailed functions such as the power control of the specific sensor and the heating coil.

It will be appreciated from the above description that the second heating unit 400 preferably operates by arranging the heating coil in at least two directions of the front, rear, left, and right directions. Here, each temperature setting may be an operation involving a sensor or a fully manual operation without a sensor, or an operation using a control function. In the structure in which the temperature sensor is interlocked and operated, the temperature is maintained at a constant value. On the other hand, when the control function is operated, the power of the heating coil is controlled by the time interval. That is, according to the control function, it is possible to control various temperature curves through a variable duty ratio control such that the temperature is automatically set higher as time passes.

In the operation using the control function, it is preferable to perform a temperature setting operation by a graphic control in a computer monitor, and it is preferable to electrically control the heating coil as a plurality of channels through a plurality of output ports connected to one microprocessor or a computer.

Furthermore, the control function or control device preferably includes a configuration that can be controlled and monitored remotely through a communication network. In particular, in a production structure in which a large-sized metal mold is automatically operated, it is difficult to observe every operating situation by personnel. Therefore, remote control or monitoring through a communication network can be very useful in this case.

In the first embodiment of the present invention, the first heating unit 200 has a flat plate structure in at least one of the front, rear, left, and right directions of the horizontal upper plate mold 100 and the lower plate mold 300 Sliding insertion and return.

The first heating part 200 may be slidably expanded and returned to the roller structure in at least one of the front, rear, right, and left directions of the horizontal upper mold 100 and the lower mold 300. Since a more specific principle can be known from the description of the first heating part 500 in an example, only the concept will be explained to this extent and the rest will be omitted.

6A, 6B and 6C are a perspective view and a sectional view showing a second embodiment of the present invention.

That is, according to the second embodiment of the present invention,

An upper plate mold 100 and a lower plate mold 300 configured to accommodate a first member as an inner filler and to fuse the first member as a second member that is a sheet member;

The upper and lower molds 100 and 300 are inserted in at least two directions toward the center between the vertical spaces of the upper and lower molds 100 and 300 so that the respective members are heated and returned to their original positions. A first heating part 500 having a structure that the shape is decomposed (501, 502) to move to the edge at the time of returning;

A mold control unit 700 for vertically compressing the upper mold 100 and the lower mold 300 through the space where the first heating unit 500 is returned while controlling the first heating unit 500, ;

And the mold control unit 700 interlockingly controls the molds 100 and 300 and the first heating unit 500 to fuse the respective members.

First, the features of the second embodiment of the present invention will be intensively described.

FIG. 6A is a diagram showing another embodiment of the shape of the first heating part 500 when the first heating part 500 is assembled in the second embodiment of the present invention. In particular, this figure shows that when the first heating part 500 is shaped and assembled, it has the same shape and function as the first heating part 200 described above. In FIG. 6A, (c2) shows that, for example, when the unit area of the cushion mat is square, the first heating part 500 also has the same square.

That is, when the first heating part 500 forms a function for heating, the first heating part 500 is assembled into the shape 200 having the same area as the cushion mat between the vertical spaces of the upper mold 100 and the lower mold 300, Is removed from between the vertical spaces of the upper mold 100 and the lower mold 300 and the shape 200 is disassembled is a gist of the second embodiment of the present invention.

6B is an exemplary view showing a disassembled shape of the first heating part 500 of the present invention. That is, when the first heating part 500 is assembled, the flat plate 200 is inserted in at least two directions toward the center to form the flat plate 200. However, when the heating operation is completed and returned to the home position, So that the flat plate 200 is disassembled and positioned at the edges 501 and 502. In FIG. 6B, 501a and 502a show areas that converge or disintegrate from the center, and in FIG. 6b, the first heating portion in the form of rollers 501 and 502 is disclosed to be curled and moved to the edge. However, this configuration may be configured such that the flat plate 200 is slid to the edge while being divided into two pieces or four pieces, for example.

When the area corresponding to the first heating portion 500 is shaped and the first roller 501 and the second roller 502 are absorbed by the first roller 501 and the second roller 502, 200 are blank, so that the top mold 100 is lowered through the blank space and can be engaged with the bottom mold 300. (Or the lower mold can be raised and engaged with the upper mold). FIG. 6C shows a state in which the upper mold 100 is moved to the lower mold 300 by using the blank space -200- .

According to the second embodiment of the present invention as described above, it is possible to obtain a time shortening effect of reducing the time taken for the first heating unit 500 to be removed to the outside through sliding to be reduced to at least 1/2, Effect is obtained.

The quality of fusion at the edges of the cushion mat is enhanced by the assembling and disassembling action of the first heating portion as described above. However, in order to maintain a more accurate quality, the structure of the second heating portion in the structure of the second embodiment of the present invention Can be applied. That is, the second heating unit 400 may be configured to supplementively heat the edge of the second member during a time period during which the first heating unit returns to the edge position, and may be controlled by the mold control unit 700 You can do it.

A heating coil 400 which is a heating mechanism specified as the configuration of the second heating unit 400 for this, a second heating unit control unit 750 for controlling the heating coil, a sensor unit 752, a CPU 753, And the functions of the mold control unit 700 and the second heating unit control unit 750 that are linked to the monitor unit and the operation unit 751, manual operation or control function setting for temperature setting, remote control and remote monitoring, It is redundant to the description of the first embodiment of the present invention described above. Therefore, it will be referred to when necessary and further explanation will be omitted.

From the above-described first and second embodiments of the present invention, it will be understood that the operation principle of the mold apparatus improving the fusing force at the edge of the cushion mat and improving the yield has been understood. However, the fusing of the complete cushion mat is insufficient .

FIG. 7A is a photograph and a drawing showing an example in which the quality of fusion is uneven in the cut surface for folding the cushion mat at multiple stages with only the upper mold and the lower mold.

That is, the completed multi-stage foldable cushion mat is folded in the opposite directions in the lines 12 and 32 as shown in FIG. 7 (a) to form the overlapping section as shown in (a) need. To this end, the upper plate 100 or the lower plate 300 of the metal mold further includes vertical partition walls 102 and 302 for vertically cutting out the second member, wherein (c) and (d )to be. (c) is a broken line formed through the partition wall 302 provided in the lower plate 300, and (d) is a broken line formed through the partition wall 102 provided in the upper plate 100.

However, when the line 32 is bent in the thus formed cushion mat, unfused portions appear between the inner filler and the outer sheet material as shown in photographs (e) and (f). This is a problem that is found by trimming the edge portion in the photograph (d). In other words, when the upper and lower portions are cut by trimming, the side edges 40 must be fused to form an unfused portion as an overall cushion mat. However, , The fusion of the side edges can not be completed by the invention of the second embodiment alone, and this problem is not solved. Further, when the mold is used for a long period of time, the base of the entire mold apparatus for fixing the mold frame may be deformed, or the temperature of the mold frame itself may change, which may lead to uneven edge fusion of the entire square of the cushion mat.

Therefore, the present invention further includes means for constituting a side plate mold for horizontally compressing the second member in the axial direction of the partition wall portion to finely fuse the cut-out portion. And further includes a third heating unit and a fourth heating unit for further heating the side plate mold, and further, the structure of the mold posture control unit 700 for making the interval between the edges of the mold constant.

7B and 7C are cross-sectional views showing a third embodiment of the present invention constituting a side plate mold to solve the problem shown in FIG. 7A,

The upper plate mold 100 or the lower plate mold 300 described above further includes vertical partition walls 102 and 302 for vertically cutting out the second member 12 and 32 to form a curved surface of the cushion mat, A side plate mold 600 for horizontally pressing the second member in the axial direction of the partition walls 102 and 302 to finely fuse the cutout 12 or 32 is provided at the side of the mold 100 or the lower plate 300 Wherein the cushion mat mold apparatus further comprises means for forming a cushion mat.

As shown in FIG. 7 (b), the side plate mold 600 can be seen in which direction the components are pressed against the upper mold 100 and the lower mold 300. In a specific configuration, A vertical pin 620 for obtaining a moment in the pressing of the upper plate and a second pin 630 for switching the moment applied to the vertical pin to horizontal, The horizontal member 610 horizontally pressing and releasing the horizontal force.

7C, the head 621 protruding from the upper portion of the vertical pin 620 senses an operation in which the edge face 101 of the upper plate is downwardly pressed and transmits the lowered pressing force moment to the horizontal member 610, It will be understood that the member 610 has a structure in which the partition wall portion (for example, 102) is squeezed from the side. At this time, the second member (10, 30) is pressed between the partition member (102) and the horizontal member (610).

It is preferable that the coupling between the vertical pin 620 and the horizontal member 610 constituting the side plate mold is coupled at an oblique angle so as to be slid at any angle between 20 degrees and 70 degrees, It is preferable to add a member so as to be interlocked and return to the home position each time the mold returns to the original position. 7 (c) and 7 (b) of FIG. 7 show a state in which the side plate mold is returned to its original position and FIG. 7 (d) shows a state in which the side plate mold is operated.

If a plurality of protrusions are formed at a predetermined distance in the front end portion of the side plate mold or a means 630 for forming a groove at a predetermined interval at which the knife or the laser cutter is projected is formed at the central portion of the front end portion of the side plate mold, And at the same time the finish welding of the portion to be trimmed is performed at the same time, so that the quality can be improved and the yield rate in the working process can be increased.

7B to 6C illustrate the sectional views taken along the axial direction of the partition walls 102 and 302. As shown in FIGS.

These protrusions or the like serve to facilitate the incision from the lower end to the upper end at the position of the lower end bending point of the finished cushion mat.

Meanwhile, the side plate molds 610 and 620 of the present invention can be configured as a sensor and a solenoid type. That is, if the horizontal member 610 is replaced with a moving shaft by a solenoid and the vertical pin 620 is replaced with a proximity sensor or a microswitch, the switch senses whether or not the upper plate is squeezed. As a result, And releasing operation can be performed. Therefore, at least the same operation can be obtained.

The configuration for this is shown in Fig. 7D is a block diagram 800 explaining solenoid control, which is an example of the configuration of the side plate mold, as an electric circuit function. The sensor unit 810, that is, a micro switch or the like detects the pressing of the upper plate, 830 is controlled by the CPU 820. As shown in FIG. Of course, you can also configure a direct connection without a CPU.

Here, (840) is a monitor and an operation unit, which can operate the side plate mold by digital switching of the intermittent switch type in conjunction with the CPU, or can operate the side plate mold by the analog action gradually increasing the pressing force. The analog action is achieved with a gradual increase in power and a means for adjusting the driving force of the solenoid, i. E. The pressing force, with a time factor (e. G., A control scheme that increases the duty ratio in time).

On the other hand, the upper and lower molds described above include a mold for molding the cushion mat. The mold is a shape formed by engraving the shape of the cushion mat at an engraved angle. Therefore, Which is a basic equipment. However, since the molds of the upper plate and the lower plate are operated by the principle that the first member and the second member, which have very high physical properties in a heated state, are pressed and returned to their original positions, It should have features that keep it fine everywhere. Since the attitude control significantly affects the quality of fusion-molding of the cushion mat, the present invention also provides a proposal for this. The mold posture control unit 2000 shown in Fig. 7E is a proposal thereof.

7E, the upper or lower molds 100, 101, 301, 302 including the mold are controlled to be interlocked with the mold equipment body through a plurality of piston means 2001, Or a transmission mechanism, and a control arrangement for controlling the gap between the molds so as to keep the gap between the upper and lower molds constant, and further to maintain the horizontal plane of the mold. . The piston means may be a mold equipment main body for operating the upper and lower plates, or may be constituted as a supplementary equipment added thereto.

In this case, the horizontal plane position of the mold is measured by a sensor 2002 for detecting the inclination of a gyro sensor, and the gap between the upper and lower molds is measured by a proximity sensor 2003 at at least two positions, The mold posture control means controls the inclination sensor, the proximity sensor, and the piston means in conjunction with the mold posture control means 2004 while being constructed of a pneumatic or electric device.

Here, the tilt sensor 2002 is a sensor for detecting whether or not the posture of the horizontal plane is constant. More specifically, it is most preferable to use a digital gyro sensor which measures the three-axis inclination of X, Y and Z and outputs it accurately. The proximity sensor 2003 is a sensor that measures the gap between the upper plate and the lower plate using capacitive, magnetic, laser, microswitches, reed switches, and the like. For example, if the gap between the upper and lower plates is measured by using this sensor, it is possible to obtain a uniform gap as if the material properties of the object to be fused in the inside thereof are soft and hard, So that a uniform fusion of high quality can be achieved. The outputs of these sensors are input to the mold attitude control means 2004. The mold attitude control means 2004 compares these inputs with a reference force (not shown) for setting the force or automatically, thereby feedback-controlling the piston means, The automatic control of the posture is automatically performed in the repeated automation equipment, and the combination and return operation between the upper and lower plates of the mold apparatus are performed with a certain standard.

The vertical partition wall 102 or 302 corresponding to the corner 40 of the cushion mat or the sidewall of the metal mold may be provided with a means for constituting a third heating unit for supplementarily heating the first member and the second member Further, the side plate mold 610 may further include means for constituting a fourth heating unit for heating while pressing the second member horizontally in the axial direction of the partition wall 102. As described above, the third heating part and the fourth heating part are configured to fuse the edges 40 and 32 of the edge part in a complementary manner. The construction of the heating coil 400 is similar to that of the heating coil 400, And therefore, a detailed explanation will be omitted.

As an example of utilizing the third heating part and the fourth heating part, the inner filling material that is received and fused into the inside of the mold in each of the above embodiments may be formed of at least the same size as the inner size of the mold, Or more. That is, if the inner filling material accommodated in the mold frame is equal to or slightly larger than the size of the mold, or at least about 5%, the thickness of at least the sheet member acts as a moment for squeezing the corner 40 laterally, The problem of edge fusion failure 32 as shown in (f) of FIG. 7A can be solved.

Particularly, the cushion mat manufactured by such a principle has a shape that is balanced by the pressure of the bubbles contained in the inner filler and the rigidity of the material of the outer sheet member, so that even if the atmospheric temperature becomes low after the cushion mat is manufactured, The volume is not changed and the pressure is lowered. As the atmospheric temperature rises, the bubble expansion of the foamed shape member causes the product to be maintained in a mutually balanced state in which only the pressure of the bubble increases due to the rigidity of the outer sheet member, do. In other words, it is possible to obtain the effect of suppressing the volume change, in which the expansion and contraction of the cushion mat is minimized even when the ambient temperature changes.

In addition, when the upper and lower plates are coupled with each other, the edge of the mold is cut with a cutter to neatly finish the edges of the cushion mat. In the present invention, when the upper and lower molds are compressed, And a cutter means for finishing trim the edges of the respective members while rotating.

FIG. 8 is a method flow chart of a first embodiment of the present invention, illustrating the principle of manufacturing the cushion mat through the mold apparatus exemplified in FIG. 5 and FIGS. 7A, 7B, 7C,

A mold apparatus including a first heating member and a second heating member to house a first member as an inner filler and to fuse the first member as a second member as a sheet member,

(902) sliding the first heating part between the upper plate and the lower plate;

Operating the first heating unit (903) to heat the first member and the second member between the upper plate and the lower plate;

A step (904) of sliding the first heating part after completion of the heating;

A step (905, 906) of fusing the first member and the second member by pressing the upper plate and the lower plate while operating a second heating unit for compensating for a change in the edge temperature of the member after the first heating unit is removed;

A process (910) of returning the upper plate and the lower plate to the original position after the fusion is completed;

As a key feature.

A step of pressing the side plate mold so that the second member is fused to the side edge of the first member while the upper plate and the lower plate are fused and fused together and releasing the compression of the side plate mold together with the return of the upper plate mold, .

Also, the above-described mold posture control (2000) configuration for uniformly welding the edge portions can be included in a fusion process for controlling the upper and lower plates by compression. On the other hand, in a state where the upper plate and the lower plate are coupled to each other, the edges of the mold are cut with a cutter so that the edges of the cushion mat can be neatly finished.

Other portions will be understood only as described in the drawing of FIG. 8, and if there is a need for further understanding, please refer to the device description of the corresponding portion.

Fig. 9 is a schematic flow chart of a second embodiment of the present invention, illustrating a principle of manufacturing the cushion mat through the mold apparatus exemplified in Figs. 6A, 6B, 6C and Figs. 7A, 7B, 7C,

A mold apparatus for accommodating a first member, which is an internal filler, and a second member which is a sheet member,

A first heating part assembling step (1002) constituting a first heating part between the upper plate and the lower plate;

(1003) controlling operation of the first heating unit so that the first heating unit heats the first member and the second member;

A step (1005, 1006) of disassembling and removing the first heating part after completion of heating and fusing the first member and the second member by squeezing the upper plate and the lower plate;

A process (1008, 1010) in which the upper and lower plates are returned to their original positions after completion of fusion;

A method of manufacturing a cushion mat as a key feature.

Also, the apparatus may further include a configuration in which the side plate mold is compressed so that the second member is fused to the side edge of the first member after the top plate and the bottom plate are compressed, and the compression of the side plate mold is released along with the return of the top plate mold In addition,

The method may further include the step of operating the second heating unit to maintain the edge temperature of the second member in cooperation with the first heating unit. Also, the mold posture control (2000) configuration may be included in the welding process in which the upper plate and the lower plate are controlled to be crimped. On the other hand, in a state where the upper plate and the lower plate are coupled to each other, the edges of the mold are cut with a cutter so that the edges of the cushion mat can be neatly finished.

Other portions will be understood only as described in the drawing of FIG. 9, and if there is a need for further understanding, please refer to the device description of the corresponding portion.

Claims for claiming the technical idea of the present invention include a cushion mat product manufactured according to the above-described method for manufacturing a mold apparatus for a cushion mat or a cushion mat.

It will be apparent to those skilled in the art that various modifications, additions and substitutions are possible, without departing from the spirit and scope of the invention as defined by the appended claims. Should be regarded as belonging to the following claims.

The first member (20)
The second member (10, 30)
The corner portion (40)
The edge portions (11, 31)
The lines 12 and 32,
The upper plate (100)
The lower plate (300)
A first heating unit 200;
A mold control unit 700;
The upper sheet member 30,
The lower sheet member 10,
The internal filler (20)
A second heating unit 400;
The edge of the mold bottom plate (301)
The second heating unit control means 750,
The sensor unit 752,
The CPU 753
The monitor unit and operation unit 751
The first heating part 500,
A flat plate shape assembly (200)
Shape decomposition (501, 502)
The edges of the first heating portion, the rollers 501 and 502,
The blank space (-200-) where the first heating part is located
The vertical partition walls 102 and 302,
The side plate mold (600)
The side wall portion 310 of the upper plate or the lower plate,
Vertical pin 620
The horizontal member 610,
A head 621 protruding from the upper portion of the vertical pin 620,
Edge 101
The protrusion or laser projection groove 630
The sensor unit 810,
The solenoid mold portion 830
The CPU 820
Monitors and controls (840)
The mold posture control unit 2000,
Piston means (2001)
Tilt detection sensor (2002)
Proximity Sensors (2003)
The mold posture control means (2004)
A step (902) of inserting the first heating part by sliding;
Operating the first heating unit (903);
A step 904 of sliding the first heating part;
Fusing the first member and the second member (905, 906);
A process (910) of returning the upper and lower plates to their original positions;
A first heating subassembly process 1002;
Controlling the operation of the first heating unit (1003);
Fusing the first member and the second member (1005, 1006);
In the processes 1008 and 1010 in which the upper and lower plates are returned to their original positions,

Claims (27)

A first mold supporting the first member;
A second mold supporting the second member;
A first heating unit inserted between the first mold and the second mold to heat the first member and the second member; And
And a mold control unit for vertically compressing the first mold and the second mold to fuse the first member and the second member,
Wherein the mold control unit controls the molds and the first heating unit to interlock with each other to fuse the first member and the second member, and the first heating unit applies heat to the first member and the second member, And the second mold is discharged to the outside of the first mold and the second mold. The apparatus of claim 1, wherein the first heating unit outputs far-infrared rays to the first member, and the general infrared rays are output to the second member,
Wherein an air discharge path is formed in the second member so that air existing between the first member and the second member is discharged to the outside during the fusion. The method according to claim 1,
Further comprising a second heating unit for supplementarily heating the edge portions of the first member and the second member,
Wherein the mold control unit interlockingly controls the molds and the heating units to fuse the first member and the second member. The apparatus of claim 3, wherein the second heating unit is formed of heating coils having an electrically independent structure on the second mold,
Wherein the heating coils are arranged in at least two directions to independently output heat, and when the first heating unit is discharged to the outside, heat is outputted individually in accordance with the movement of the first heating unit. 5. The cushion mat mold apparatus according to claim 4, wherein the heating coils are interlocked with a control device that is interlocked with the temperature sensor or controls to be individually operated as a control function. 6. The method of claim 5, wherein the control function is configured to set the temperature at a periodic time operation and the control device is configured to be implemented in a microprocessor,
Wherein the electrically independent structure is configured to be made through a plurality of output ports. The method according to claim 6,
Wherein the control function or control device can be controlled and monitored remotely via a communication network. The cushion mat molding apparatus according to claim 1, wherein the first heating unit is horizontally slidably inserted and discharged in a flat plate structure in at least one direction of the front and rear sides of the first member and the second member. The cushion mat molding apparatus according to claim 1, wherein the first heating unit is slidably inserted and discharged in a roller structure in at least one direction of the first member and the second member in a horizontal direction. 2. The apparatus of claim 1, wherein the first heating portion is separable and engageable with a plurality of members,
The members are inserted and joined in at least two directions when inserted between the first member and the second member and are discharged to the outside of the first member and the second member after being separated by the members at the time of discharge Features a cushion mat mold device. The cushion mat according to claim 1, further comprising a mold for molding a shape of a cushion mat on at least one of the molds, wherein the mold is controlled to be interlocked with the mold equipment body by a plurality of piston means Device. 12. The method of claim 11,
Wherein the piston means includes a structure in which the gap between the molds is controlled so as to maintain a vertical gap between the front, rear, left and right molds while maintaining a horizontal plane posture independent of the front, rear, left and right sides. 13. The method of claim 12,
Wherein the horizontal plane position of the mold is measured by a tilt sensor and the gap between the upper and lower molds is measured by a proximity sensor at at least two positions and the piston means is constituted by a hydraulic pressure, Wherein the mold posture control means controls the tilt sensor, the proximity sensor, and the piston means to be interlocked with each other. The method according to claim 1,
The first mold or the second mold further includes a vertical partition wall portion for vertically cutting out the second member to form a curved surface of the cushion mat, and the side wall of the first mold or the second mold has the cut- Further comprising means for constructing a side plate mold for horizontally compressing the second member in the axial direction of the vertical partition wall portion for finishing welding. 15. The method of claim 14,
Wherein the side plate mold includes a vertical pin for obtaining a moment in the compression of the upper plate and a horizontal member for horizontally pressing and releasing the second member by switching a moment applied to the vertical pin horizontally Features a cushion mat mold device. 15. The method of claim 14,
Wherein the side plate mold includes a sensor for sensing the pressing action of the upper plate and a structure for being engaged and disengaged by a solenoid type horizontal member for horizontally pressing and releasing the second member as a result of the sensor. 15. The method of claim 14,
Wherein a plurality of projections are formed at a predetermined interval in a tip end portion of the side plate mold. 15. The method of claim 14,
Wherein a central portion of a front end portion of the side plate mold is formed with a groove at a predetermined interval and the laser cutter is interlocked with the groove to project the groove. 15. The method of claim 14,
And means for constructing a third heating portion for supplementarily heating the first member and the second member to the vertical partition wall portion or the side wall portion of the metal mold corresponding to the corner portion of the cushion mat,
Wherein the side plate mold further comprises means for constituting a fourth heating section for heating while pressing the second member horizontally in the axial direction of the partition wall section. The method according to claim 1,
Wherein at least one of the molds is interlocked with cutter means for trimming the edge of the edge when the first member and the second member are fusion-bonded. A first mold supporting the first member;
A second mold supporting the second member;
A first heating unit positioned between the first mold and the second mold to heat the first member and the second member; And
And a second heating portion for heating an edge portion of the first member or the second member,
Wherein the first member and the second member are heated and fused by the heating portions. 22. The apparatus of claim 21, wherein the second heating unit is formed of heating coils having an electrically independent structure on the first mold or the second mold,
The heating coils are arranged in at least two directions so that heat can be output independently and when the first heating part is discharged to the outside, heat is individually outputted in accordance with the movement of the first heating part, So that the temperature of the edge of the cushion mat is uniformly maintained. A first mold supporting the first member;
A second mold supporting the second member; And
And a first heating unit inserted between the first mold and the second mold to heat the first member and the second member and to be separated and coupled to the plurality of members,
The members of the first heating portion are inserted and joined at least two directions when inserting between the first member and the second member, are separated by the members, and then discharged to the outside of the first member and the second member And the first member and the second member are fusion-bonded after the members are discharged to the outside. Supporting each of the first member and the second member on the first mold and the second mold;
Heating the first member and the second member by placing a first heating unit between the first mold and the second mold;
Discharging the first heating unit to the outside of the first mold and the second mold after the heating;
Pressing the first mold and the second mold to fuse the first member and the second member; And
And returning the first mold and the second mold. 25. The method of claim 24,
Further comprising the step of supplementally heating the edge portions of the first member and the second member with the second heating portion,
Wherein the first member and the second member are welded after the edge portion is heated. 25. The method of claim 24,
The side plate mold is compressed so that the second member is fused to the side edge of the first member after the first mold and the second mold are pressed together, and the compression of the side plate mold is released together with the discharge of the first mold ≪ / RTI > further comprising a configuration. 25. The method of claim 24,
Further comprising the step of cutting and trimming the edge of the edge before performing the step of returning the first mold and the second mold to the original position after completion of the fusion.

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