KR20220143271A - Method for manufacturing bedding filler using gel cushion - Google Patents

Abstract

A method for manufacturing a bedding filling using a gel cushion is disclosed. The method for manufacturing the bedding filling using the gel cushion includes the following steps: preparing a composition for a gel structure; setting an adhesive medium on a lower plate of a mold; manufacturing an injection product in which the composition of the gel structure and the adhesive medium are integrated by injecting the manufactured composition of the gel structure into the mold; processing the adhesive medium of the injection molding into a predetermined size; applying an adhesive to the adhesive medium of the injection-molded product; and bonding the injection-molded product and the cushion.

Description

Method for manufacturing bedding filling using gel cushion {METHOD FOR MANUFACTURING BEDDING FILLER USING GEL CUSHION}

The following examples relate to a method for manufacturing a bedding filling using a gel cushion.

A cushion used for a bed or a cushion is formed of a material that provides comfort to the human body by supporting and distributing a person's weight. The materials used for these cushions should have properties such as softness, compressibility, vibration absorption, dehumidification, deformation followability, and durability. or a gel structure. Among them, in particular, the gel structure has excellent body pressure dispersibility, breathability, durability and sanitary safety, and is becoming more common.

A method for manufacturing a gel structure by injection molding into a hexagonal column shape having the most geometrically stable structure is widely known. However, the gel structure having a general hexagonal column shape has problems in that it is not easy to remove the mold from the mold, resulting in low productivity and poor molding completion. In order to solve this problem, if the bulkhead is manufactured by increasing the thickness, it causes a decrease in left pressure performance.

In addition, the gel structure of such a hexagonal column structure has a limitation in increasing the height of the bulkhead column due to the limitation of the manufacturing method, and the insufficient height must be joined with a separate cushion material to manufacture the cushion. However, direct adhesion between the gel structure and the cushion material is not possible, and is usually adhered using an adhesive medium. However, in order to complete the gel structure, the adhesive medium, and the cushioning material as a single product, an adhesive operation is required between each material. Even if each material is adhered to each other, the cushion material composed of a double material layer changes the shape of the cushion material when pressure is applied due to the characteristics of the cushion material. It may not be provided and may be removed. This has a problem of significantly lowering the productivity of the product. In addition, there was a problem in that the more the adhesion portion, the higher the possibility of defects in the product, such as poor adhesion.

The above-mentioned background art is possessed or acquired by the inventor in the process of deriving the disclosure of the present application, and it cannot necessarily be said to be a known technology disclosed to the general public prior to the present application.

An object of the embodiment is to provide a method for manufacturing a filling for bedding using a gel cushion having a structure that improves productivity by manufacturing an adhesive medium and a gel structure in one piece, and is easy to remove from a mold.

The problems to be solved in the embodiments are not limited to the problems mentioned above, and other problems not mentioned will be clearly understood by those skilled in the art from the following description.

Disclosed is a method for manufacturing a bedding filling using a gel cushion according to an embodiment. The method for manufacturing a bedding filling using a gel cushion includes the steps of preparing a composition for a gel structure, setting an adhesive medium on the lower plate of the mold, injecting the prepared composition of the gel structure into the mold to adhere to the composition of the gel structure manufacturing an injection-molded product in which the medium is integrated, processing the bonding medium of the injection-molded product to a predetermined size, applying an adhesive to the bonding medium of the injection-molded product, and It is configured including the step of adhering the injection-molded material and the cushion.

According to one side, preparing the composition of the gel structure includes mixing a copolymer obtained by copolymerizing a polystyrene-based polymer and polypropylene with an additive, adding oil while stirring the mixture, and dropping the oil It may include stirring the mixture at a speed of 5000 to 6000 rpm for 10 to 20 minutes in a bath having a temperature of 40 to 50° C. using a high-speed mixer.

According to one side, in the manufacturing of the injection-molded product, a plurality of barrier ribs may be formed to form a through hole having a cross-section of a regular hexagon that is depressed downwardly in the gel structure.

According to one side, the upper thickness of the partition wall may be formed to be 1mm to 3mm.

According to one side, the through hole may be formed so that the diameter of the upper portion is larger than the diameter of the lower portion.

According to one side, the diameter of the upper portion of the through hole may be formed of 8mm to 12mm.

According to one side, the adhesive medium may use a PET sheet or a PU sheet.

According to one side, an adhesive layer on at least one surface may be formed between the gel structure and the cushion.

According to one side, the cushion may be formed of urethane, PE, PP and latex materials.

According to one side, the cushion may be formed with a groove corresponding to the gel structure.

As seen above, according to the embodiments, the method for manufacturing bedding fillings using a gel cushion integrates the gel structure and the adhesive medium, thereby reducing the manufacturing process and improving productivity, and it is easy to remove the mold from the mold.

Effects of the bedding filling manufacturing method using a gel cushion according to an embodiment are not limited to those mentioned above, and other effects not mentioned will be clearly understood by those skilled in the art from the following description.

1 is a flowchart of a method for manufacturing a bedding filling using a gel cushion according to an embodiment.
FIG. 2 is a flowchart of a step of preparing the composition of the gel structure of FIG. 1 .
FIG. 3 is a view showing a process of manufacturing an injection product in which the composition of the gel structure and the adhesive medium are integrated by injecting the composition of the gel structure of FIG. 1 into a mold.
4 is a view for explaining a method for manufacturing bedding fillings using a gel cushion according to an embodiment.
5 is a view showing the bedding filling manufactured by the method for manufacturing the bedding filling using a gel cushion according to an embodiment.
The following drawings attached to this specification illustrate preferred embodiments of the present invention, and serve to further understand the technical spirit of the present invention together with the detailed description of the present invention, so the present invention is limited only to the matters described in those drawings should not be interpreted as

Hereinafter, embodiments will be described in detail with reference to the accompanying drawings. However, since various changes may be made to the embodiments, the scope of the patent application is not limited or limited by these embodiments. It should be understood that all modifications, equivalents and substitutes for the embodiments are included in the scope of the rights.

Terms used in the examples are used for the purpose of description only, and should not be construed as limiting. The singular expression includes the plural expression unless the context clearly dictates otherwise. In the present specification, terms such as “comprise” or “have” are intended to designate that a feature, number, step, operation, component, part, or combination thereof described in the specification exists, but one or more other features It is to be understood that this does not preclude the possibility of the presence or addition of numbers, steps, operations, components, parts, or combinations thereof.

Unless defined otherwise, all terms used herein, including technical or scientific terms, have the same meaning as commonly understood by one of ordinary skill in the art to which the embodiment belongs. Terms such as those defined in a commonly used dictionary should be interpreted as having a meaning consistent with the meaning in the context of the related art, and should not be interpreted in an ideal or excessively formal meaning unless explicitly defined in the present application. does not

In addition, in the description with reference to the accompanying drawings, the same components are assigned the same reference numerals regardless of the reference numerals, and the overlapping description thereof will be omitted. In the description of the embodiment, if it is determined that a detailed description of a related known technology may unnecessarily obscure the gist of the embodiment, the detailed description thereof will be omitted.

In addition, in describing the components of the embodiment, terms such as first, second, A, B, (a), (b), etc. may be used. These terms are only for distinguishing the elements from other elements, and the essence, order, or order of the elements are not limited by the terms. When it is described that a component is “connected”, “coupled” or “connected” to another component, the component may be directly connected or connected to the other component, but between each component another component It will be understood that may also be "connected", "coupled" or "connected".

Components included in one embodiment and components having a common function will be described using the same names in other embodiments. Unless otherwise stated, descriptions described in one embodiment may be applied to other embodiments as well, and detailed descriptions within the overlapping range will be omitted.

Referring to FIG. 1 , the method for manufacturing a bedding filling using a gel cushion according to an embodiment includes the steps of preparing a composition 121 of a gel structure (S10), setting the adhesive medium 13 on the lower plate of the mold ( S20), injecting the prepared composition 121 of the gel structure into a mold to prepare an injection product in which the composition 121 of the gel structure and the adhesive medium 13 are integrated (S30), the bonding medium 13 of the injection product is predetermined It is configured to include a step of processing to the size of (S40), applying an adhesive to the adhesive medium 13 of the injection product (S50), and bonding the injection product and the cushion 20 (S60).

First, in the method for manufacturing a bedding filling using a gel cushion, a composition 121 of a gel structure is prepared (S10). The step (S10) of preparing the composition 121 of the gel structure will be described in detail with reference to FIG. 2 .

Referring to Figure 2, the step (S10) of preparing the composition 121 of the gel structure is a step (S11) of mixing a copolymer obtained by copolymerizing a polystyrene-based polymer and polypropylene with an additive, and dropping oil while stirring the mixture Step (S12), and a step (S13) of stirring the mixture in which the oil is added dropwise at a speed of 5000 to 6000 rpm in a bath having a temperature of 40 to 50° C. for 10 to 20 minutes using a high-speed mixer (S13).

First, a copolymer obtained by copolymerizing a polystyrene-based polymer and polypropylene and an additive are mixed (S11). Polystyrene-based polymer in the step of mixing a copolymer obtained by copolymerizing polystyrene-based polymer and polypropylene with an additive has a three-block structure, such as SEBS (styrene-(ethylene/butylene)-styrene Block Copolymer) or SEEPS (Polystyrene-block-poly( ethylene-ethylene/propylene)-block polystyrene). Here, as a polystyrene-based polymer, PP-SEBS, which is a copolymer obtained by copolymerizing SEBS and polypropylene, is mentioned as an example, but is not limited thereto.

The additive is for removing oil blooming and improving the heat resistance of the gel structure 10 , and fumed silica or wet silica may be used. Here, it is preferable to use fumed silica as the fumed silica.

Next, the oil is added dropwise while stirring the mixture (S12). The oil is added dropwise while stirring the mixed mixture. Here, the oil may be added dropwise to the mixture so that the oil is well mixed.

Next, the mixture to which the oil is added is stirred for 10 to 20 minutes at a speed of 5000 to 6000 rpm in a bath having a temperature of 40 to 50° C. using a high-speed mixer (S13). The mixture in which the oil is added is stirred through a high-speed mixer for 10 to 20 minutes to finally prepare the composition 121 of the gel structure. Here, the composition 121 of the gel structure comprises 5 to 8 parts by weight of an additive based on 100 weight of a mixture consisting of 30 to 40% by weight of a copolymer obtained by copolymerizing a polystyrene-based polymer and polypropylene and 60 to 70% by weight of an oil. It is preferable to do At this time, if the content of oil is less than 60% by weight, the hardness increases, so the effect of suppression dispersion decreases and the shrinkage rate is very large, making it very difficult to separate from the mold during injection. If it exceeds 70% by weight, it is difficult to mix the oil and the copolymer Therefore, injection is impossible, and even if it is injected, oil blooming occurs during use, so it is desirable to set the oil content within the above range.

의 온도의 배스(Bath)에서 5000~6000rpm의 속도로 교반하는 것이 바람직하다. 이 때 배스의 온도가 40

미만이면 오일과 공중합체가 고르게 섞이지 않고 50

를 초과하면 제조 후 열화에 의하여 물성이 저하되기 때문에 위 온도 범위로 하는 것이 바람직하다. 또한 교반 속도가 5000rpm 미만이면 교반하 는데 소요되는 시간이 증가하며 교반시간이 충분하지 않으면 공중합체의 분산도가 떨어져 오일 블루밍이 발생할 수 있고 6000rpm을 초과하면 공중합체 분자상의 열화(degradation)로 물성이 저하될 수 있기 때문에 위 온도 범 위로 하는 것이 바람직하다. In addition, agitation is 40-50

It is preferable to stir at a speed of 5000 to 6000 rpm in a bath of a temperature of At this time, the temperature of the bath is 40

If it is less than 50, the oil and copolymer are not mixed evenly.

If it exceeds, the physical properties are reduced due to deterioration after manufacturing, so it is preferable to set it within the above temperature range. In addition, if the stirring speed is less than 5000 rpm, the time required for stirring increases. If the stirring time is not sufficient, the dispersion of the copolymer may decrease and oil blooming may occur. It is preferable to set it in the above temperature range because it can be lowered.

Returning to FIG. 1 again, the adhesive medium 13 is set on the lower plate of the mold ( S20 ). Referring to FIG. 3 , after setting the adhesive medium 13 on the lower plate of the mold, the prepared composition 121 of the gel structure is injected into the mold and injected, thereby integrating the gel structure 10 and the adhesive medium 13. have. For example, the adhesive medium 13 may use a PET sheet or a PU sheet. Since it is difficult to directly adhere polystyrene-based polymer and polypropylene, which are the main components of the gel structure 10, and urethane, PE, PP, and latex, which are the main components of the cushion 20, the adhesive medium 13 is a gel The structure 10 and the cushion 20 formed of urethane, PE, PP, and latex material to be described later serve as an intermediate medium so that they can be combined. By integrating the adhesive medium 13 into the gel structure 10, there is no need to apply a separate adhesive between the gel structure 10 and the adhesive medium 13, thereby simplifying the manufacturing process, and forming a plurality of adhesive layers 30 It is possible to reduce defects in adhesion defects that may occur by doing so.

인 것이 바람직하다. 사출 압력이 15kg/cm²를 초과하는 경우 버 발생 및 사출이 매우 어렵기 때문에 15kg/cm²이하로 하는 것이 바람직하다.Next, by injecting the prepared composition 121 of the gel structure into the mold, the composition 121 of the gel structure and the adhesive medium 13 are integrated to prepare an injection molding (S30). The composition 121 of the gel structure and the adhesive medium 13 are integrated by a predetermined temperature and pressure inside the mold, and have a predetermined shape. For example, the injection pressure inside the mold is 15 kg/cm ² or less, preferably 15 kg/cm ² , and the nozzle temperature is 250

It is preferable to be When the injection pressure exceeds 15 kg/cm ² , it is preferable to set it to 15 kg/cm ² or less because burr generation and injection are very difficult.

Hereinafter, the step (S40) of processing the adhesive medium of the injection-molded product to a predetermined size to the step of bonding the injection-molded product and the cushion (S60) will be described with reference to FIGS. 4 to 5 .

Referring to FIG. 4 , the bonding medium 13 of the injection-molded product is processed to a predetermined size ( S40 ). The gel structure 10 and the adhesive medium 13 are separated from the mold in an integrated state. At this time, the width of the adhesive medium 13 is formed to be larger than that of the gel structure 10 and is separated from the mold to form the protrusion 131 . Here, the protrusion 131 of the adhesive medium 13 is processed to be the same as the width of the gel structure 10 .

Next, an adhesive is applied to the adhesive medium 13 of the injection-molded product (S50). At least one adhesive layer 30 is formed between the gel structure 10 and the cushion 20 . For example, the first adhesive layer 31 may be formed by applying an adhesive to the lower surface of the adhesive medium 13 of the injection-molded product, and may be bonded to the cushion 20 . Alternatively, the second adhesive layer 32 may be formed by applying an adhesive to the side surface of the injection-molded product, and the cushion 20 may be inserted into the cushion 20 having a groove 21 having a size corresponding to that of the injection-molded product to be bonded.

Next, the injection-molded material and the cushion 20 are adhered (S60). The cross-section of the bonding medium 13 of the injection-molded product comes into contact with the cross-section of the cushion 20 . The adhesive medium 13 serves to connect the injection-molded material and the cushion 20, so that the height of the bedding filling can be adjusted. For example, the cushion 20 may be formed of urethane, PE, PP, and latex materials, and in addition, various known natural or synthetic materials having elasticity and ductility may be used. At least one adhesive layer 30 is formed between the injection-molded product and the cushion 20 , and a groove 21 having a size corresponding to the size of the injection-molded product is formed in the cushion 20 , so that the injection-molded product is inserted and adhered to the groove 21 . can be

Referring to FIG. 5 , the injected gel structure 10 forms a plurality of partition walls 12 to form a through hole 11 having a cross section of a regular hexagon that is depressed downward. The plurality of partition walls 12 are continuously formed while being spaced apart by a predetermined interval, and have a honeycomb structure in which a plurality of regular hexagonal through holes 11 are formed. The partition wall has a honeycomb structure in which a plurality of regular hexagonal through holes 11 are formed, so that air flows smoothly inside the through holes to effectively dissipate moisture and sweat, thereby having thermal stability, and uniformly distributing body pressure to a certain part of the body By relieving the applied pressure, the seating comfort can be improved.

Here, the upper thickness (T ₁ ) of the partition wall 12 may be formed in a range of 1 mm to 3 mm. The plurality of partition walls 12 are formed to become thicker as they go down, and the through hole 11 formed between the partition walls 12 has an upper diameter (D ₁ ) larger than a lower diameter (D ₂ ). It is formed so that the diameter becomes smaller as it goes down. Here, the diameter (D ₁ ) of the upper portion of the through hole 11 may be formed of 8mm to 12mm. As such, the gel structure 10 in which the upper thickness T ₁ of the partition 12 is smaller than the lower thickness T ₂ has the advantage of being easily separated from the mold, and the left pressure performance is also improved. The upper thickness (T ₁ ) of the partition wall (12) in contact with the body of the occupant is formed to be thin, providing a soft seating feeling to the occupant, and the lower thickness (T ₂ ) of the partition wall (12) in contact with the cushion (20) is thickened By being formed, it has the effect of stably supporting the gel structure 10 .

According to this embodiment, in the method for manufacturing bedding fillings using a gel cushion, the gel structure 10 and the adhesive medium 13 are formed by setting the adhesive medium 13 on the lower plate of the mold and injecting the gel structure 10 into the mold. By integrating, the manufacturing process can be reduced and productivity can be improved.

In addition, the method for manufacturing a bedding filling using a gel cushion has excellent adhesive strength because it is directly connected to the gel structure 10 and the adhesive medium 13 , so that the quality of the product can be improved.

In addition, the bedding filling manufacturing method using the gel cushion can be easily separated from the mold by forming the upper thickness (T ₁ ) of the partition wall (12) of the gel structure (10) to be narrower than the lower thickness (T ₂ ), and the left pressure performance can also be improved.

As described above, although the embodiments have been described with reference to the limited drawings, those skilled in the art may apply various technical modifications and variations based on the above. For example, the described techniques are performed in a different order than the described method, and/or the described components of the system, structure, apparatus, circuit, etc. are combined or combined in a different form than the described method, or other components Or substituted or substituted by equivalents may achieve an appropriate result.

Therefore, other implementations, other embodiments, and equivalents to the claims are also within the scope of the following claims.

10 gel structures
11 hole
12 bulkhead
121 Composition of the gel structure
13 Adhesive media
131 overhang
20 cushions
21 home
30 adhesive layer
31 first adhesive layer
32 second adhesive layer

Claims (10)

preparing a composition for a gel structure;
setting an adhesive medium on the lower plate of the mold;
preparing an injection product in which the composition of the gel structure and the adhesive medium are integrated by injecting the prepared composition of the gel structure into the mold;
processing the adhesive medium of the injection-molded product to a predetermined size;
applying an adhesive to the adhesive medium of the injection-molded product; and
adhering the injection-molded product to the cushion;
A method for manufacturing bedding fillings using a gel cushion comprising a. According to claim 1,
The step of preparing the composition of the gel structure,
mixing a copolymer obtained by copolymerizing a polystyrene-based polymer and polypropylene with an additive;
Dropping the oil while stirring the mixture; and
stirring the mixture in which the oil is added dropwise at a speed of 5000 to 6000 rpm in a bath having a temperature of 40 to 50° C. for 10 to 20 minutes using a high-speed mixer;
A method for manufacturing bedding fillings using a gel cushion comprising a. According to claim 1,
The step of producing the injection molding,
A method for manufacturing bedding fillings using a gel cushion in which a plurality of partition walls are formed to form a through hole having a cross-section of a regular hexagon recessed downward in the gel structure. 4. The method of claim 3,
The upper thickness of the partition wall is a bedding filling manufacturing method using a gel cushion that is formed in a range of 1 mm to 3 mm. 4. The method of claim 3,
The through hole is a method for manufacturing bedding fillings using a gel cushion in which the diameter of the upper part is larger than the diameter of the lower part. 6. The method of claim 5,
The diameter of the upper portion of the through hole is a bedding filling manufacturing method using a gel cushion that is formed in a range of 8mm to 12mm. According to claim 1,
The adhesive medium is a method for manufacturing bedding fillings using a gel cushion using a PET sheet or a PU sheet. According to claim 1,
A method for manufacturing bedding fillings using a gel cushion in which at least one adhesive layer is formed between the gel structure and the cushion. According to claim 1,
The cushion is a bedding filling manufacturing method using a gel cushion formed of urethane, PE, PP and latex material. According to claim 1,
The cushion is a bedding filling manufacturing method using a gel cushion in which a groove corresponding to the gel structure is formed.

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