KR20200129322A - element mat for assembly and assembled mat having the same - Google Patents

Abstract

Disclosed are an individual mat for assembly and an assembly type mat formed by coupling the individual mats. The individual mat is formed into a polygonal plate shape, wherein a stepped portion consisting of a groove and a protrusion to be coupled with an adjacent individual mat is installed in a lower part of a lateral surface across the entire section of each polygonal side. In an upper side of the protrusion, a stepped groove, which is stretched out along a side, is formed. In an opposite surface facing the groove, a stepped protrusion, which is fitted into the stepped groove, is formed. According to the present invention, the assembly type mat is easy to install and is capable of preventing separation after installation. As an actual depth of a gap is reduced, the assembly type mat is capable of reducing accidents such as fractures or sprains due to children′s tripping over or the children′s fingers or toes being trapped into the gap after installation and preventing damage to a floor due to moisture or dust flowing into through the gap in an assembly joint. In addition, it is possible to prevent the gap between the installed mats due to the shrinkage of the mat caused by a temperature change in a place where the mats are installed.

Description

Cushion mat for assembly, and assembly mat having the same (element mat for assembly and assembled mat having the same}

The present invention relates to a prefabricated mat, and more particularly, a separate cushion mat for assembly used to protect children from being injured even if they fall down by laying on the indoor floor or to prevent inter-floor noise from occurring in a multi-story building such as an apartment, and a combination thereof It relates to an assembly mat made by doing.

Cushion mats are used in general homes and multipurpose facilities such as kids cafes and nursing homes for the purpose of preventing falls, preventing noise between floors, preventing musculoskeletal diseases and alleviating fatigue in places such as kitchens.

Cushion mats are often formed to cover a large area by simply assembling protrusions and grooves that engage with each other around small square or rectangular individual mats to facilitate installation and removal as needed.

1 shows such a conventional example. As viewed from above, the four sides of the square plate-shaped body (1) are formed by alternately forming coupling grooves (3) and protrusions (4) with diagonal lines on each side (2) at regular intervals. According to the area of, a plurality of protrusions are assembled and laid in a manner that connects the protrusions to the coupling grooves in all directions.

In this case, if the connecting portion of the coupling groove and the protrusion is viewed as a zigzag complex line, the eyes are easily fatigued, and as the length of the connecting portion is longer, there are many gaps where foreign substances such as dust are trapped, so cleaning, etc. There were also problems such as taking a lot of time and effort to manage.

In addition, all of the usual cushion mats for assembly are made of polyurethane foam for their own purposes, so they are soft and elastic, so when pressure or force is applied to the assembly connection, a gap is likely to be opened, and when water or beverage falls on the mat, the gap There is a risk of damage, such as rotting or deforming the floor underneath. Dust can also enter the gap, and if the user steps on the excitement space of the mat and floor during activity, compressed air can come out of the gap and exhale dust.

In addition, if the gap is easily formed and only one side of the assembly connection of two adjacent mats is pressed, a step may occur and a foot jam may occur.Adults do not have a big problem, but the child's fingers and toes get caught in the gap and trip over. Loss or severe cases may lead to safety accidents such as fractures of the fingers and toes.

In addition, when pressure or force is applied to the assembly connection, there is a phenomenon that the connection is easily disengaged because the connection portion is increased and the connection cannot be firmly bonded due to the nature of the high-foaming polyurethane foam having ductility and elasticity. Although the coefficient of contraction and expansion according to temperature is large, if the structure cannot sufficiently exhibit the bonding force to maintain the connection between the mats, gaps between the mats may occur depending on the temperature even if there is no external force.

In order to solve these problems, insert foaming can be made to secure the bond by inserting a hard implant during urethane foam foaming, but insert foaming complicates and cumbers the usual injection process, and increases the cost due to the addition of members. I can.

On the other hand, in the case of forming a cushion mat with only polyurethane foam, liquid may be absorbed into the surface if water or other beverages are poured on it due to the nature of the porous material, it is difficult to finish smoothly in appearance, and there is a possibility of surface damage such as scratches due to external force. In recent years, there are cases where products are made by combining a polyurethane skin layer such as TPU on the upper surface of the polyurethane foam.

This configuration is usually achieved through polyurethane foam injection molding in which a TPU skin layer is first installed on the injection mold and then foamed polyurethane is injected thereon.

However, in this configuration, due to the bubbles of the polyurethane foam during injection molding, the actual contact area between the polyurethane foam layer and the TPU skin layer becomes smaller and the adhesive strength is weakened, so that peeling or lifting between the two layers can easily occur, thereby reducing the marketability.

And even in such a configuration, if the TPU skin layer is thickened, the cushioning feeling decreases and the elasticity is low, and when a force is applied from the side, the peeling phenomenon between the TPU skin layer 101 and the polyurethane foam layer 105 occurs more easily, as shown in FIG. Likewise, during injection molding, the radius of curvature increases at the corners due to the thick TPU skin layer 101, which causes a problem in that the gap between the connection portions is larger in the two assembly cushion pads 10' and 20', so a thin skin layer is used. In the case of using a thin skin layer, it is possible to sufficiently solve the problems of conventional cushion mats such as scratch prevention and openness and detachment of the connection part due to external force or environmental factors, except for some such as penetration of beverages into the surface listed above or realization of a smooth surface. There was no.

In addition, the TPU skin layer can prevent substances such as beverages from seeping into the foam when beverages, etc. are poured onto the surface of the assembly pad, but if water penetrates into the gap between the joints between individual cushion pads and touches the floor, Prior to separating individual pads and wiping off the beverages from the floor, these materials are easily absorbed by the foam-assembled pad bottom, making it difficult to remove. This leaves moisture or odor due to decay, and hygiene due to the growth of mold and bacteria. Problems could have arisen.

Korean Patent Publication No. 10-2015-0103416: Assembly mat Japanese Patent Publication No. 2011-247026: Joint mat

A Study on the Development of Automatic Density Control System in Polyurethane Molding Process (Ministry of Commerce, Industry and Energy Final Report) (Consignment Agency: Korea Footwear & Leather Research Institute, 2003. 10. 31)

The present invention is to solve the problems of the conventional prefabricated mat, while implementing the function of the existing cushion mat, while reinforcing the coupling force of the connecting portion, a problem due to a gap, such as a jam problem due to the formation of a step, a problem with a finger or toe injury of children, An object of the present invention is to provide a cushion mat for assembly that can alleviate problems due to inflow and absorption of foreign substances, and an assembly mat made by combining the same.

An object of the present invention is to provide a cushion mat for assembly having a structure capable of preventing damage and damage such as surface scratches due to the limitations of the existing polyurethane skin layer and suppressing the formation of gaps due to external force, and an assembly mat provided with the same. .

The cushion mat for assembly of the present invention to achieve the above object

It is characterized by comprising a skin layer, a low-foaming foam layer (high-density layer), and a high-foaming foam layer (low-density layer) whose density is relatively low and the degree of pore content increases while going from top to bottom in at least a portion of the upper surface. That is, a low-foaming foam layer is provided between the skin layer and the high-foaming foam layer.

In the present invention, the high-foaming foam layer may have a density of 50 to 99kg/m, and the low-foaming foam layer may have a density of 100 to 300kg/m.

In the cushion mat for assembly of the present invention, the skin layer may have a thickness in the range of 10 to 150 μm, the high-foaming foam layer may have a thickness in the range of 5 to 100 mm, and the low-foaming foam layer has a thickness in the range of 0.5 to 5 mm, compared to the high foaming foam layer. It may be formed to a thickness of 10% or less.

In the present invention, the boundary between the high-foaming foam layer and the low-foaming foam layer may not be clearly distinguished. For example, even in a high-foaming foam layer, a place in contact with the polyurethane skin layer may have a higher density and fewer bubbles, and a place in contact with the low-foaming foam layer may have a relatively low density and a large number of bubbles. Likewise, even in the low-foaming foam layer, the portion in contact with the high-foaming foam layer may have a relatively high density and few bubbles. There may be a non-uniformity in which the thickness of the low-foaming foam layer varies depending on the location. In this case, the division between the high-foaming foam layer and the low-foaming foam layer can be artificially made depending on the density range, and it can be seen that there are different layers of the low-foaming foam layer and the high-foaming foam layer, but the exact boundary position. B It can be difficult to tell the exact thickness of the low foaming foam layer.

In the present invention, under the high foaming foam layer, a low foaming foam layer or a skin layer forming a lower surface may be provided.

In the present invention, the skin layer may be formed of a material having other characteristics, such as a film of a material such as TPU (thermo plastic polyurethane) or PVC (polyvinyl chloride), which is harder than the polyurethane foam layer and is not easily damaged, and the low foaming foam layer and high The foamable foam layer may be formed integrally with a polyurethane foam that is of the same polyurethane material and differs only in the degree of pore content.

At this time, the low-foaming foam layer and the high-foaming foam layer are made through a consistent operation, but the degree of pore content is adjusted by adjusting only the forming conditions with a time gap, or the material is introduced without a time gap, but the mold is made by using the temperature difference between the mold and the material. The portion in contact with may be adjusted to form a low-foaming foam layer by rapidly hardening before sufficient pores are formed.

Alternatively, in the present invention, the low-foaming foam layer and the high-foaming foam layer are formed of a polyurethane material having a different material composition so that the degree of pore formation is different, and a low-foaming material is first added, and then a high-foaming material is added to form two separate layers. It may be formed.

In the present invention, when dividing a portion having a full thickness as a body portion and a portion having a stepped partial thickness as a connection portion, the connection portion may have a low-foaming foam layer on the surface in contact with the adjacent cushion mat for connection. At least a portion of the mat side surface may be water-repellent or waterproofed through a coating film or film treatment on the low-foaming foam layer, or may be treated to adsorb foreign substances such as fine dust or dust. At this time, a viscous material layer may be used for adsorption of foreign matter.

In the present invention, at least some surfaces of the connection part may have a layered structure such as a skin layer, a low foaming foam layer, and a high foaming foam layer, such as the upper surface of the main body.

According to an additional aspect of the present invention, in each of the cushion mats for assembly made of a polygonal plate shape, the connection portion is grooved for coupling with the cushion mat adjacent to the side of the cushion mat for assembly over the entire side of the polygon (the entire section). And a stepped portion consisting of a protrusion, wherein the protrusion is installed below the thickness direction, and a stepped groove extending along the side is installed on the upper surface facing the top of the protrusion, and the groove is installed above the thickness direction , On the corresponding surface facing the bottom of the groove, a stepped protrusion fitted to fit the stepped groove may be installed.

According to an additional aspect of the present invention, the cushion mat for assembly may be made to have a concave shape having a slightly lower center portion than the peripheral portion. In this case, it is desirable that the level difference between the peripheral portion and the lower middle portion is not concentrated on a specific portion. That is, if a step is prominent in a frozen part, a person stepping on the mat may get caught because of the step, so it is desirable to make a gentle slope from the periphery to the center so that the step does not occur.

It is preferable that the surface of the cushion mat for assembly of the present invention is subjected to an antifouling treatment so that foreign matters are not easily adhered, and can be easily wiped and removed even in a state of foreign matters. For this purpose, a method of applying an antifouling material to the surface after forming a cushion mat may be used, or a method of applying an antifouling material to the surface may be used.

The assembly-type mat of the present invention is made by two or more cushion mats for assembly of the present invention in which grooves and protrusions are coupled to each other at the side of a polygon and connected in a lateral direction.

According to the present invention, while implementing the functions of the existing cushion mat, it is possible to better prevent damage and damage such as surface scratches due to the limitations of the existing thin polyurethane skin layer, and to some extent resist deformation due to external force to suppress the formation of gaps. A prefabricated mat with a structured structure can be provided.

According to an additional configuration of the present invention, it is possible to suppress the problem of the existing prefabricated mat, in which moisture or dust enters the gap of the assembly connection and damages the floor after installation, and it is possible to easily find and remove moisture or dust.

1 is a perspective view showing a state in which two individual mats are combined with each other in an example of a conventional assembly mat;
FIG. 2 is a conceptual perspective view for explaining a problem in which a radius of curvature increases at a corner and a gap at a connection part increases when a conventional TPU skin layer of an individual mat is thickened;
3 is a plan view showing a combination of two adjacent cushion mats for assembly forming an embodiment of the assembly mat of the present invention;
Fig. 4 is a partial cross-sectional perspective view showing the connection structure of the two assembly cushion mats forming the embodiment as shown in Fig. 3;
5 is a cross-sectional view showing a layer structure of two assembling cushion mats forming another embodiment;
6 is a cross-sectional photograph showing a part of a reference sample in which the upper and lower surfaces of the high foaming polyurethane foam layer are wrapped with a low foaming polyurethane foam layer in relation to the embodiment of FIG. 5;
7 and 8 are cross-sectional views showing a layer structure of two assembly cushion mats constituting another embodiment;
9 is a cross-sectional view showing that the body portion is formed to be concave as a whole with a lower surface and an inclination than the peripheral portion in another embodiment.

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

3 and 4 show a plan view of a combined state of two adjacent individual mats according to an embodiment of the present invention, and a partial cross-sectional perspective view of the mated state.

Here, the cushion mats for individual assembly (10, 20: hereinafter, simply mixed as individual mats) are all in the same shape and can be combined with adjacent individual mats in the same phase, that is, in the same state of the upper and lower positions and the rotational position. I can. As a whole, a protrusion 11 and a groove 17 are provided on each side corresponding to the four sides of the main body part, which is close to a square, by half sections when viewed in the side length direction. These protrusions 11 and grooves 17 are not formed on the entire side that constitutes the side, but are formed only in steps corresponding to the lower half thickness in the individual mat thickness direction.

In more detail, the protrusion 11 of the stepped portion is in the form of a plate that protrudes approximately in the right half section when each side of the square is placed above the plan view, and the groove 17 is a protrusion 21 of another individual mat in the left half section. It is installed as a concave space of a corresponding shape so that it can be connected to.

Two identical individual mats 10 and 20 formed in this way are placed adjacent to each other left and right on the floor, and the protrusions 11 of the right individual mat 10 at the sides facing each other while deforming by applying force using the elasticity and elasticity of the individual mats The protrusion 21 of the left individual mat 20 is coupled to the groove 17 of the right individual mat 10 in the groove of the left individual mat 20.

On the upper surface of the protrusion 11, a stepped groove 13 is formed long along the length direction of the side, and a stepped protrusion 29 corresponding to the stepped groove 13 is formed on the corresponding surface of the groove (the surface corresponding to the upper surface). Has been. The stepped protrusion 29 is formed in a position and size capable of being coupled to correspond to the stepped groove 13 on the upper surface of the protrusion 11.

Both ends of the stepped groove 13 in the lateral direction are blocked by a stepped grooved jaw or a protruding jaw 15. Therefore, when the stepped protrusion 29 is inserted into the stepped groove 13, it is prevented from being blocked by the protruding jaw 15 and sliding along the stepped groove 13 in the side direction.

The step groove 13 is in the path through which beverage or dust reaches the floor when beverage or dust enters through the gap between the assembly connection of the two individual mats, and the protruding jaws 15 at both ends have the step groove 13 If there is a small space or gap between the bottom of the stepped groove 13 and the end of the stepped protrusion 29, it is made into a kind of container that can hold an object. There is a high possibility that they will gather here without passing through the stepped groove.

Here, the protrusions and grooves formed on each of the four sides of the square individual mat are formed over the entire length (overall) of each side, but in a practical sense, it means that they are formed over each side for convenience when assembling adjacent individual mats. In the longitudinal direction of both ends of the side, for example, a case where protrusions and grooves are not formed in a section of less than 10% of the entire section can be included, and a method to avoid conflict with adjacent individual mats and facilitate assembly by rounding the shape when viewed from above. You can also use

Even in this case, the corners of the square, where the protrusions and grooves are omitted, are a small part compared to the whole, and the amount of beverage or dust that can flow into this part is limited, and it takes considerable time for beverages to flow into this part only. The low mat user can easily find and wipe spilled beverages, and if in doubt, it is possible to easily disassemble and wipe the water.

Looking at the layer structure of the individual mat in the partial cross-section shown in Fig. 4, most of the body is made of a thick layer made of high-foaming (low-density) polyurethane foam, and the upper part of the high-foaming polyurethane foam layer 205 has low foaming properties. A (high density) polyurethane foam layer 203 is formed to cover the high foaming polyurethane foam layer 205, and a polyurethane skin layer 201 made of a thermoplastic polyurethane (TPU) material is again formed thereon to form the skin layer of an individual mat. Is being achieved.

The high-foaming polyurethane foam has a density of 50 to 99 kg/m and a thickness of 5 to 100 mm, making up most of the thickness of the individual mat, and the low foaming polyurethane foam has a density of 100 to 300 kg/m and a thickness in the range of 0.5 to 5 mm. It is formed with a thickness of 10% or less compared to the high foaming foam. The polyurethane film, which is the skin layer, is formed to a thickness in the range of 10 to 150 um.

In this configuration, the high-foaming polyurethane foam layer is responsible for noise prevention and buffering functions, which are the main functions of the prefabricated mat, and is formed so that it is easy to expand and contract by external force and to have elasticity. The low-foaming polyurethane foam layer on the upper surface has a high density and excellent mechanical stiffness, and a polyurethane film such as TPU has a more enhanced density, hardness and mechanical strength to achieve a hard and smooth appearance.

Therefore, the low-foaming polyurethane foam and polyurethane film on the upper surface of the individual mats protect the high-foaming polyurethane foam layer underneath it to prevent damage such as imprinting and tearing by external objects, and even when liquid substances are poured onto the assembly mat. It is prevented from seeping through the surface into the highly foaming polyurethane foam layer.

This configuration can be formed by configuring a mold to form a form in which individual mats are inverted in the vertical direction, and by including a polyurethane film in a manner similar to insert injection.

For example, in one embodiment, a polyurethane film that will form an upper surface of an individual mat is previously installed on the inner bottom surface of the mold so that it can be matched. On top of that, a certain amount of material or raw material in a liquid mixture state for forming polyurethane foam is consistently injected. At this time, the mold is operated somewhat higher at 80 to 90 degrees Celsius, and the raw material is injected at about 25 to 30 degrees Celsius, which is similar to room temperature, so that foaming and hardening are performed.

In this case, the outer layer close to the mold hardens relatively quickly before sufficient foaming occurs to form a low-foaming polyurethane foam layer, and most of the inside hardens slowly while sufficient foaming to form a high-foaming polyurethane foam layer. The urethane film and the low-foaming polyurethane foam layer are naturally matched and bound to form an individual mat of the present invention.

According to another embodiment, a polyurethane film is placed on the bottom of the mold, and a material (raw material) in the form of a liquid mixture for forming a polyurethane foam is injected to partially foam and cure for a certain thickness in contact with the polyurethane film. Then, for the high-foaming polyurethane foam molding, the process of filling the mold and curing is performed by injecting a material with a different amount or composition of an additive for forming internal bubbles so that the porosity is high. Individual mats can be formed.

In the above embodiments, when injecting the material for forming the low-foaming polyurethane foam layer and the high-foaming polyurethane foam layer, the composition of the liquid mixture, temperature or mold temperature, injection pressure, the waiting time between injection of the low-foaming foam layer and the high-foaming foam layer is not set or constant. It is possible to control the thickness of each foam layer and the degree of bubble generation by operating different conditions, such as taking time.

The raw materials and conditions for the formation of polyurethane foam are conventionally widely known, and here as the main raw material for making a liquid mixture, isocyanate weight 40-60 is mixed with respect to polyol weight 100, and isocyanate like water A foaming agent for generating a gas such as carbon dioxide by acting together with, a surfactant such as silicone, a catalyst for accelerating the reaction, and the like may be additionally included.

As a raw material, polyol is an initiator such as a multifunctional alcohol or aromatic amine having two or more hydroxyl groups (Hydroxyl Group, -OH) or amine group (-NH2) and propylene oxide (Propylene Oxide). , PO) or ethylene oxide (EO) is a material obtained by reacting under appropriate conditions, and in this example, polypropylene glycol (PPG), which is a type of polyether polyol most frequently used with a specific gravity of 80 to 90%, is used. use.

In the present embodiment, methylene diphenyl diisocyanate (MDI) is used as the isocyanate, which is an aromatic diisocyanate chemical substance. Methylene diphenyl diisocyanate is largely divided into MDI monomer and polymeric MDI, and MDI monomer consists of three isomers, 2,2'-MDI, 2,4'-MDI, and 4,4'-MDI. Of these, the 4,4'-isomer is called pure MDI or Monomeric MDI. Polymeric MDI is a mixture of monomeric MDI and higher molecular weight polynuclear methylene diphenyl diisocyanate. In the case of using MDI, foams with different characteristics can be obtained without diversifying the stock solution components, and the viscosity increase and curing speed are high in the order of tens of seconds to several minutes, resulting in excellent productivity, easy integral molding, and suitable for low temperature molding.

In the above example, 80 to 90 degrees Celsius is suggested as the mold temperature for polyurethane foam molding, but the mold temperature may be operated around 45 to 70 degrees Celsius, and basically these temperature ranges can be seen as low temperature curing process bands. have. The liquid mixture is formed by supplying a type A liquid added with an additive to a polyol and a type B liquid consisting of isocyanate through a mixing head, mixing it, and supplying it to a mold, and the temperature is usually 25 to 30 degrees, similar to room temperature. Seed.

As an equipment for injecting liquid mixtures, a high-pressure blower can be used in consideration of convenience in use, and a high-pressure blower can be used with a pressure allowable limit of 350kg/m and a working pressure range of 100 to 250bar.

5 is a cross-sectional view showing a layer structure of two cushion mats for assembling, which constitutes another embodiment from the embodiment of FIG. 4.

Here, as compared to the embodiment of Fig. 4, the low-foaming polyurethane foam layer 303 is not formed only on the high-foaming polyurethane foam layer 305, but is also formed on the side and the lower surface of the low-foaming polyurethane foam layer. 303 surrounds the high foaming polyurethane foam layer 305.

FIG. 6 is a cross-sectional photograph showing a part of a reference sample of a mat in which the upper and lower surfaces of the high-foaming polyurethane foam layer are wrapped with a low-foaming polyurethane foam layer as shown in the example of FIG. 5.

In the embodiment of Fig. 5, as in the embodiment of Fig. 4, the low-foaming polyurethane foam layer 303 that forms the outer layer protects the high-foaming polyurethane foam layer 305 therein, so that it is damaged by external objects or external forces. It has a function of preventing damage to the back and preventing the liquid material from penetrating into the high-foaming polyurethane foam layer 305 through its surface even when it is poured onto the assembly mat.

In addition, in this configuration, a significant portion of the side of the connecting portion is formed of low-foaming polyurethane, so that the overall mechanical rigidity of the connecting portion is increased and the deformation by external force is also reduced, so even after long use, the connecting portion between individual mats is stretched and the connection becomes loose. It can prevent a lot of gaps from occurring when looking at the entire assembly mat.

In addition, since there are not many gaps, the inflow of foreign substances such as beverages or dust is suppressed, and the surface in contact with the floor is also made of low-foaming polyurethane, so that the introduced beverage is not easily absorbed by individual mats. Therefore, it is possible to remove the individual mat on the floor within a short period of time after the drink is poured, so that it is better to prevent moisture from getting wet on the bottom of the individual mat, the odor due to the growth of mold and bacteria, or a hygiene problem. Can be prevented.

This configuration can be formed by an insert injection method similar to that of the previous embodiment of FIG. 4, but in order to form the overall low-foaming polyurethane foam layer 303 on the mold contact surface, the polypropylene to form the skin layer 301 on the inner bottom surface of the mold A urethane film is installed and matched in advance, and a certain amount of the liquid mixture for forming the low-foaming polyurethane foam layer 303 is injected thereon, and the mold is rotated in the state of a low-viscosity liquid mixture before foaming is sufficiently cured. When the liquid mixture is partially applied to the inner surface of the mold (strictly, on the inner surface excluding the air outlet) by moving or moving, the liquid mixture is partially expanded and cured, and the remaining amount of the liquid mixture for molding the highly foamable polyurethane foam layer 305 It can be formed through a process of filling the mold and curing while high foaming is achieved by injecting.

On the other hand, referring to FIG. 6, it can be seen that there are different layers in appearance, the low-foaming foam layer and the high-foaming foam layer, but even within the high-foaming foam layer, the area in contact with the skin layer made of TPU or PVC is more dense and the air bubbles are higher. There are few, and the places where the low-foaming foam layer touches are relatively low in density and there are many bubbles. Likewise, even in the low-foaming foam layer, a portion in contact with the high-foaming foam layer has a relatively high density and few bubbles can be seen. Depending on the location, the thickness of the low-foaming foam layer is partially changed, so it is not completely uniform. Therefore, in this case, the thickness or boundary position of each foam layer, that is, the high-foaming foam layer and the low-foaming foam layer can be artificially distinguished by porosity or density range.

7 is a cross-sectional view showing a layer structure of two assembling cushion mats forming an embodiment different from the embodiments of FIGS. 4 and 5.

Here, as compared with the embodiment of FIG. 4, the low-foaming polyurethane foam layer 403 is formed only on the upper and side surfaces of the high-foaming polyurethane foam layer 405, and is not formed on the lower surface. And, as in the previous embodiment, the skin layer 401 made of a polyurethane film is installed only on the upper surface of the high-foaming polyurethane foam layer 405.

In this embodiment, the upper and side low-foaming polyurethane foam layers protect the high-foaming polyurethane foam layer to prevent damage, and when a liquid material is poured onto the prefab mat, the high-foaming polyurethane foam layer through the top or side surfaces. The low-foaming polyurethane on the side of the connection part is prevented from being penetrated, and the connection part is slackened between the individual mats, resulting in a loose connection, and it is possible to prevent a lot of gaps from occurring when viewed as a whole. However, when foreign substances such as beverages or dust are introduced into the gap, there is a problem that the introduced beverage is absorbed because the surface in contact with the floor is made of highly foamable polyurethane.

This configuration can also be formed by an insert injection method similar to the embodiment of FIG. 5, but since a low-foaming polyurethane foam layer is not formed on the upper inner surface of the mold, a certain amount of a liquid mixture for forming a low-foaming polyurethane foam is injected. It is possible to shake the mold in the state of a liquid mixture with a low viscosity before foam hardening is sufficiently performed, but the inversion operation is not performed.

Fig. 8 is similar to the embodiment of Fig. 7, but shows an embodiment in which the polyurethane skin layer 501 is extended on the side of the individual mat that forms the protrusion.

In order to form this state, when using the insert injection method as in the previous embodiment, the polyurethane skin layer 501 is not formed only on the bottom of the mold, but the side on which the protrusion is formed needs to be covered so that the polyurethane skin layer 501 is aligned. For the purpose of matching with the mold, it is preferable to use a thin layer of the polyurethane skin, and before injecting the liquid mixture in the mold state, pressure is applied to the inside of the skin layer and the inner surface of the mold that is not in close contact with the space. To remove the air.

In this embodiment, when compared to the embodiment of FIG. 7, it is possible to better prevent the formation of gaps in the connection part by increasing the rigidity in the side of the connection part, to better prevent the connection part from loosening, and to prevent beverages from being absorbed into the side wall. It can be well prevented.

On the other hand, in the above embodiments, it is also conceivable to use a viscous coating film or an adsorptive coating film on the side of an individual mat. In this case, the bonding force between the individual mats can be further increased, and when small dust particles enter the gap between the assembly joints between the individual mats, the dust particles are adsorbed and attached, so that the dust particles are spread back into the air by children's activities and You can prevent problems that make it worse.

9 shows an example in which a cushion mat for assembly is formed according to an additional aspect of the present invention so that the center portion is slightly lower than the peripheral portion.

This configuration is made so that when liquid substances such as beverages are poured on the mat, liquid substances that do not penetrate into the gaps or the mat itself remain in the center of the mat so that they can be easily removed with a rag or tissue paper.

In this cross-sectional view, the degree of concaveness and the height difference (g) between the periphery and the center are exaggerated to highlight the features, but the assembly cushion mat is gentle from the periphery to the center so that the step difference is not concentrated in a specific part. It is one slope, and this concave structure is not very noticeable in appearance, and it is desirable to prevent a step from occurring because a person stepping on the mat can hardly stumble or suffer inconvenience due to the difference in the peripheral and central parts. Do.

On the other hand, the surface of the cushion mat for assembly of the present invention is treated with antifouling treatment so that foreign matters are not easily adhered, and can be easily wiped and removed even in a state of foreign matters. To this end, the skin layer used when making the cushion mat for assembly may be pre-treated with antifouling treatment, or a method of coating an antifouling substance on the surface of the skin layer after forming the cushion mat once can be used.

In the above, the present invention has been described through limited embodiments, but this has been illustratively described to aid understanding of the present invention, and the present invention is not limited to these specific embodiments. For example, although the embodiment mainly describes an individual mat having a square plane, the present invention may be applied in the same manner to the case of an individual mat having an equilateral triangle or regular octagon as another polygon.

Therefore, those of ordinary skill in the field to which the present invention belongs may implement various changes or application examples based on the present invention, and it is natural that such modifications or application examples belong to the appended claims.

10, 20: individual mats 11, 21: projections
13: step groove 15: protruding jaw
17: groove 19, 29: step projection
201, 301, 401, 501: epidermal layer
203, 303, 403, 503: low foaming polyurethane foam layer
205, 305, 405, 505: high foaming polyurethane foam layer

Claims (8)

In the assembly cushion mat for forming the assembly mat,
Assembly characterized by comprising a skin layer, a low-foaming foam layer (high-density layer), and a high-foaming foam layer (low-density layer) in which the density is relatively low and the degree of pore content increases while going from top to bottom in at least a part of the upper surface. For cushion mat. The method of claim 1,
The skin layer is a TPU (thermo plastic polyurethane) or PVC (polyvinyl chloride) film, the high foaming foam layer is a polyurethane foam having a density of 50 to 99 kg / m ³ , the low foaming foam layer is a polyvinyl chloride having a density of 100 to 300 kg / m ³ Cushion mat for assembly, characterized in that consisting of urethane foam. The method of claim 1 or 2
The skin layer has a thickness in the range of 10 to 150 um, the high-foaming foam layer has a thickness in the range of 5 to 100 mm, and the low-foaming foam layer has a thickness in the range of 0.5 to 5 mm and less than 10% compared to the high foaming foam layer Assembly cushion mat, characterized in that formed in a thickness. The method according to claim 1 or 2,
The assembly cushion mat is made of a polygonal plate shape,
On the side of the individual mat for assembly over the entire side of the polygon, a step portion consisting of grooves and protrusions for coupling with adjacent individual mats is installed below the thickness direction,
Cushion mat for assembly, characterized in that a step groove extending along a side is installed on an upper surface facing the top of the protrusion, and a step protrusion fitted to fit the step groove is installed on a corresponding surface facing the bottom of the groove . The method of claim 4,
When classifying a portion having a full thickness as a body portion and a portion having a partial thickness of the body portion as a connection portion so as to form the step portion,
The assembly cushion mat, characterized in that the connection portion has the low-foaming foam layer on at least a portion of the surface in contact with the adjacent assembly cushion mat to form the assembly mat. The method of claim 5,
The connecting portion has a layered structure of the skin layer, the low foaming foam layer, and the high foaming foam layer, such as the upper surface of the main body, on at least a part of a surface in contact with an adjacent assembly cushion mat to form the assembly mat,
At least a portion of the body part is a cushion mat for assembly, characterized in that made of a concave height lower than the connection part. The method according to claim 1 or 2,
A low-foaming foam layer or a skin layer forming a lower surface is provided under the high-foaming foam layer,
Cushion mat for assembly, characterized in that the antifouling treatment is made on the skin layer. Assembled mat, characterized in that the cushion mat for assembly of claim 4 is formed by being coupled to each other in two or more sides.

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