TWI660833B - Manufacturing method of cushion body and cushion body - Google Patents

Abstract

A manufacturing method of a cushion body includes the following steps: placing a foamed material on a surface layer material so that the surface layer material includes a body area covered by the foam material and at least one surrounding area extending outward from the body area, and the surface layer is The surrounding area of the material is folded in the direction of the foam material to cover the foam material to form a folded piece. Then, the folded part is pressed to obtain a pressed part. The compression-molded part is foam-formed to obtain a preform, and finally the preform is cooled to obtain a cushion body. The manufacturing method of the pad body can produce a beautiful and durable pad body only at a lower production cost.

Description

Manufacturing method of cushion body and cushion body

The invention relates to a cushion body and a manufacturing method thereof, and particularly to a cushion body containing a foam material and a manufacturing method thereof.

You are familiar with various mats made of foamed materials, such as sports mats, seat cushions, mouse pads, etc. The general manufacturing method includes the following steps: After the surface layer material is placed on the foamed material and molded, then Use stitching or gluing to perform edging to improve the appearance and durability of the cushion body.

Chinese Patent Publication No. CN2799230 Y discloses a cushion body mainly composed of a memory inert foam in the central layer, a microfiber cloth in the surface layer, and a granular cloth in the bottom layer. And it is revealed that after the central layer is combined with the surface layer and the bottom layer, the edges can be sewed with a webbing to make the product more beautiful and not easily damaged.

Chinese Patent Publication No. CN 2870903 Y discloses a fitness exercise mat, which includes a cushion body composed of a fabric layer and an elastic layer. And the method for manufacturing the fitness exercise mat is disclosed, which includes the following steps: the fabric layer is adhered to the elastic layer by a heat-sealing method and formed into a cushion body; .

In the above two patent cases, the sewing bag of CN2799230 Y The edge treatment is a separate step after the foam, the surface layer and the bottom layer are integrated into one; the edge covering treatment of CN 2870903 Y is a separate step after the fabric layer is bonded to the elastic layer and the cushion body is formed. It can be known from this that the hemming treatment for the appearance and durability of the pads in the above two patents, in addition to being unable to be applied to the continuous process, requires additional machines and manpower required for the hemming treatment, resulting in production. Cost increase.

Therefore, there is a need to provide a cushion body manufacturing method that can take into account both the beauty and durability of the cushion body at a lower production cost, and which can be applied to a continuous process.

Therefore, a first object of the present invention is to provide a method for manufacturing a cushion body. The method for manufacturing the cushion body has a lower production cost, and can produce a beautiful and durable cushion body.

Therefore, the manufacturing method of the cushion body of the present invention includes the following steps: a feeding step, placing a foamed material on a surface layer material, so that the surface layer material includes a body area covered by the foam material and at least one body covered by the body A peripheral region extending outwardly; a folding step of folding the peripheral region of the surface layer material in the direction of the foamed material and covering the foamed material to form a folded piece; a pressing step of making the folded piece perform Compressing to obtain a pressed part; a foaming step, which is used to foam-mold the pressed part to obtain a preform; and a cooling step, which cools the preform to shape to obtain a cushion body.

Therefore, a second object of the present invention is to provide a cushion body, which has the advantages of beauty and durability.

Therefore, the cushion body of the present invention includes a surface layer including a main body portion and at least one peripheral portion extending outwardly from the main body portion. The main body portion and the peripheral portion surround to define an accommodating space communicating with the outside, and The body portion is continuous with the surrounding portion; and a foam body is disposed in the accommodation space and includes an area not covered by the surface layer.

The effect of the present invention lies in that the manufacturing method of the mat body passes the feeding step and the folding step, and cooperates with the pressing step, the foaming step and the cooling step, so that the surface layer material in the prepared mat body can be made. The function of the surrounding area is equivalent to that of the "edging" in the conventional pad body, but it does not need to go through the complicated and costly "edging processing" step as in the conventional method, so the manufacturing method of the pad body only needs to be lower. The production cost can produce beautiful and durable cushion body.

The following will describe the content of the present invention in detail: Preferably, the manufacturing method of the mat further includes a preheating step. The preheating step is performed after the feeding step and before the folding step. The foam is preheated.

Preferably, in the manufacturing method of the cushion body, the foaming step is to place the pressing part in a mold for foam molding.

Preferably, in the manufacturing method of the cushion body, the surface layer material includes two peripheral regions respectively extending outward from the main body region, and the two peripheral regions are disposed in parallel and spaced apart.

Preferably, in the manufacturing method of the cushion body, the surrounding area of the surface layer material surrounds the body area.

Preferably, in the cushion body, a peripheral portion of the surface layer surrounds the body portion.

Preferably, in the cushion body, the surface layer includes two peripheral portions respectively extending outward from the main body portion and arranged in parallel at intervals, and the peripheral portions and the main body portion define an accommodation space communicating with the outside, And the body portion is continuous with the surrounding portions.

10‧‧‧Feeding steps

20‧‧‧Conversion steps

30‧‧‧Compression step

40‧‧‧ Foaming step

50‧‧‧ cooling step

60‧‧‧Preheating steps

1‧‧‧ surface material

11‧‧‧Body area

12‧‧‧ Surrounding area

2‧‧‧Foam

3‧‧‧folded

4‧‧‧ cushion body

41‧‧‧ surface

411‧‧‧Body

412‧‧‧periphery

42‧‧‧ foam body

Other features and effects of the present invention will be clearly presented in the embodiments with reference to the drawings, in which: FIG. 1 is a flowchart illustrating the steps of the first embodiment of the manufacturing method of the present invention; FIG. 2 is a perspective view, In the feeding step of the first embodiment of the manufacturing method of the present invention, the foam material is stacked on the surface layer material; FIG. 3 is a perspective view illustrating a folded piece of the first embodiment of the manufacturing method of the present invention; 4 is a perspective view illustrating a state in which the foamed material is superposed on the surface layer material in the feeding step of the second embodiment of the manufacturing method of the present invention; FIG. 5 is a perspective view illustrating the second embodiment of the manufacturing method of the present invention FIG. 6 is a flowchart illustrating a step flow when the manufacturing method of the present invention includes a preheating step; FIG. 7 is a perspective view illustrating a first embodiment of the cushion body of the present invention; and FIG. 8 is a perspective view illustrating a second embodiment of the cushion body of the present invention.

Before the present invention is described in detail, it should be noted that in the following description, similar elements are represented by the same numbers.

Referring to FIG. 1, FIG. 2 and FIG. 3, a first embodiment of a method for manufacturing a cushion body according to the present invention includes the following steps:

(1) Feeding step 10: Provide a surface layer material 1 and a foamed material 2, preferably, the surface layer material 1 and the foamed material 2 may have the same or different shapes, but the area of the surface layer material 1 The area larger than the foamed material 2 is sufficient to cover the peripheral edges of the foamed material. As shown in FIG. 2, the foamed material 2 is superimposed on the surface layer material 1 so that the surface layer material 1 includes a body region 11 that is shielded by the foamed material 2, and a foamed material 2 that is not covered by the foamed material 2. The surrounding area 12 is shielded and extends outward from the body area 11 and surrounds the body area 11.

(2) Folding step 20: Fold the surrounding area 12 of the surface layer material 1 in the direction of the foamed material 2 by using a folding device, so that the surrounding area 12 tightly covers the peripheral edges of the foamed material 2 and forms a Folding part 3 shown in FIG. 3.

(3) Pressing step 30: Pressing the folding member 3 with a pressing device, so that the surface layer material 1 and the foamed material 2 are preliminarily bonded, and a pressing member is obtained.

(4) Foaming step 40: The pressing piece is placed in an oven, the pressing piece is foam-formed, and the foamed material 2 is heated and foamed to make it further from the surface layer material 1 Glue and get a preform.

(5). Cooling step 50: cooling the preform to shape, and obtaining a cushion body.

In the manufacturing method of the cushion body of the present invention, the surface layer material 1, the foam material 2, and the like The folding device, the pressing device, the oven, the temperature during the pressing, the temperature of the oven, the foaming method, and the cooling method are not particularly limited. Those skilled in the art can freely select and adjust according to requirements.

The foamed material 2 is, for example but not limited to, an elastic foaming composition such as rubber, plastic, etc. The types and amounts of the foaming agent, additives and other components used therein are also not particularly limited. Those skilled in the art can freely choose according to product requirements And adjustments.

The surface layer material 1 can prevent a user from contacting the foamed material 2 when using the cushion body. The surface layer material 1 is, for example but not limited to, such as polyester, cotton, natural rubber, ethylene / vinyl acetate copolymer (EVA), polyurethane, wood or bamboo. When the surface layer material 1 is a harder material such as wood or bamboo, a crease may be formed on the surface layer material 1 first, so as to facilitate the folding step 20. Preferably, the surface layer material 1 is a non-toxic environmentally friendly material. Preferably, the surface layer material 1 is an air-impermeable material to block the taste of the foamed material 2.

The folding device is, for example but not limited to, a bell mouth, a robot arm, a suction device or an electrostatic attraction device.

The pressing device is, for example, but not limited to, a pressing disk, a roller, and the like. For example, the folding member 3 is placed between an upper roller and a lower roller, and the upper roller and the lower roller are used to simultaneously roll the folding member 3. Alternatively, the folded piece 3 is placed between an upper pressing plate and a lower pressing plate, and the upper pressing plate and the lower pressing plate are used to simultaneously press the folded piece 3.

Preferably, in order to make the cushion body more beautiful or have anti-slip effect, the foam molding method is to first place the pressing piece in a mold, and then foam forming the pressing piece in an oven. The result obtained by foaming The preform will have the shape specified by the mold. It is worth mentioning that the conventional manufacturing method needs to take into account the operability and convenience of "edge processing", so the edges of the cushion body should not have patterns or special, fancy shapes. However, in the manufacturing method of the cushion body of the present invention, the surrounding area 12 of the surface layer material 1 has the function of "hemming", and there is no need to implement "hemming treatment", so the pressing piece can be placed in the mold by The re-foaming method makes the edge of the cushion body have a pattern or a special, fancy shape and is more beautiful.

The cooling method is, for example, but not limited to, cooling the preform in air.

The second embodiment of the method for manufacturing the cushion body of the present invention is different from the first embodiment in that in the feeding step 10, as shown in FIG. 4, the foamed material 2 is stacked on the surface layer material 1 Above, the surface layer material 1 includes a body area 11 covered by the foam material 2 and two body areas 11 which are not covered by the foam material 2 and extend outward from the body area 11 and are spaced parallel to each other. The surrounding area 12 is folded in the direction of the foamed material 2 when the two surrounding areas 12 are folded, and the folded part 3 is obtained as shown in FIG. 5. The second embodiment of the method for manufacturing the pad body of the present invention can be applied to a continuous process.

In the first and second embodiments of the method for manufacturing the mat body, the method for manufacturing the mat body may further include a preheating step 60 after the feeding step 10 and before the folding step 20. The preheating step 60 is to preheat the surface layer material 1 and the foamed material 2 by a preheating device after the foamed material 2 is placed on the surface layer material 1 and before the folded piece 3 is formed. The viscosity of this foam material 2. The preheating device and the preheating temperature are not particularly limited here, and those skilled in the art can freely select and adjust according to product requirements. Examples include, but are not limited to, hot rollers.

In the manufacturing method of the cushion body, in the feeding step 10, the surface layer material 1 includes the body region 11 and the surrounding region 12, and in the folding step 20, the surrounding region 12 covers the foamed material 2 and cooperates with The preheating step 60, the pressing step 30, the foaming step 40, and the cooling step 50 enable the surface layer material 1 to closely and smoothly adhere to the foam material 2, wherein the surrounding area 12 of the surface layer material 1 can be closely adhered. The edge of the foamed material 2 has the function of "hemming", and the prepared cushion body has the advantages of beauty and durability. And compared with the conventional manufacturing process, the surface layer material and the foamed material are adhered and formed, and then the "edge processing" is performed. The manufacturing method of the mat body of the present invention can make the surrounding area 12 of the surface layer material 1 with the cooperation of each step. It has the function of "hemming" without the need to set up a machine and manpower for "hemming treatment", so it can produce beautiful and durable cushions with low production costs.

Referring to FIG. 7, a first embodiment of a cushion body 4 according to the present invention includes a surface layer 41 and a foam body 42.

The surface layer 41 includes a main body portion 411 and a peripheral portion 412. The peripheral portion 412 extends outwardly from the main body portion 411 and surrounds the main body portion 411, and the main body portion 411 and the peripheral portion 412 define a containing space that communicates with the outside. The body portion 411 and the surrounding portion 412 are integral and continuous.

The foam body 42 is disposed in the accommodating space, and a peripheral edge of the foam body 42 is tightly covered by a peripheral portion 412 of the surface layer 41. And because the accommodating space defined by the body portion 411 and the surrounding portion 412 is in communication with the outside world, the foam body 42 includes a surface layer 41 that is not covered by the surface layer 41. The covered area shows that the foam body 42 is not completely covered by the surface layer 41, that is, the foam body 42 is partially exposed, so the pad can be made by the material characteristics of the foam body 42. The body 4 has an anti-slip effect.

Referring to FIG. 8, the second embodiment of the cushion body 4 of the present invention is different from the first embodiment in that the surface layer 41 of the cushion body 4 includes two peripheral portions 412. The peripheral portions 412 are respectively extended outward from the main body portion 411 and are disposed at parallel intervals. The main body portion 411 and the peripheral portions 412 define an accommodating space that communicates with the outside. The body portion 411 and the peripheral portions 412 are integral and continuous.

The foam body 42 is disposed in the accommodating space, and two mutually parallel edges of the foam body 42 are tightly covered by the peripheral portion 412.

In the cushion body 4 of the present invention, the peripheral portion 412 of the surface layer 41 has the function of “enclosing”, and the peripheral portion 412 and the main body portion 411 are integral and continuous. Therefore, compared with the conventional cushion body, the cushion body 4 of the present invention has one The molding visual feeling is more beautiful.

Specific products of the cushion body 4 of the present invention are, for example, but not limited to, mouse pads, yoga pads, step pads, shoe pads, or seat pads.

In summary, the manufacturing method of the cushion body of the present invention passes the feeding step 10 and the folding step 20, and cooperates with the pressing step 30, the foaming step 40, the cooling step 50, and the preheating step 60, and only needs to be lower. The production cost can produce beautiful and durable cushion body. And the manufacturing method of the pad body also has the following advantages: (1) it can be used in a continuous process with high productivity; (2) no adhesive is required in the manufacturing process, which can save manufacturing costs and is more environmentally friendly; (3) The body area 11 and the surrounding area 12 of the surface layer material 1 are continuously and integrally covered on the foam material 2 to make the prepared cushion body more beautiful; (4) The edge of the prepared cushion body can be made. With patterns or special and fancy shapes, it is more beautiful; (5) the mat is easy to recycle; (6) when the surface material 1 is a non-toxic and environmentally friendly material, the mat has better safety (7) When the surface layer material 1 is an air-impermeable material, the user cannot easily smell the foam material 2 when using the cushion body.

However, the above are only the preferred embodiments of the present invention. When the scope of implementation of the present invention cannot be limited by this, that is, the simple equivalent changes and modifications made according to the scope of the patent application and the content of the patent specification of the present invention, All are still within the scope of the invention patent.

Claims (5)

A method for manufacturing a cushion body includes the following steps: a feeding step, placing a foamed material on a surface layer material, so that the surface layer material includes a body region covered by the foam material and at least one direction from the body region A peripheral region extending outward; a folding step of folding the peripheral region of the surface layer material in the direction of the foamed material and covering the foamed material to form a folded piece; a pressing step of pressing the folded piece A compression part is obtained; a foaming step is performed to foam the compression part to obtain a preform; and a cooling step is performed to cool the preform to set to obtain a cushion body. The manufacturing method of the cushion body according to claim 1, further comprising a preheating step, the preheating step is to preheat the surface layer material and the foamed material after the feeding step and before the folding step. The method for manufacturing a cushion body according to claim 1, wherein the foaming step is to place the pressed part in a mold for foam molding. The method for manufacturing a cushion body according to claim 1, wherein the surface layer material includes two peripheral regions respectively extending outward from the main body region, and the two peripheral regions are arranged in parallel at intervals. The method for manufacturing a cushion body according to claim 1, wherein the surrounding area of the surface layer material surrounds the body area.