TWI834557B - Three-dimensional pad and manufacturing method thereof - Google Patents

Abstract

A three-dimensional pad has a base layer and a composite mesh forms a front side of the base layer. The composite meshes has at least two mesh stacked together, each of two meshes has a plurality of apertures arranged in a matrix. The base layer forms a plurality of raised portions arranged in a matrix by applying force to the composite mesh. Each of the raised portions has at least one stepped portion between the bottom surface and the top surface of the raised portion.

Description

Three-dimensional cushion material and manufacturing method thereof

The present invention relates to a three-dimensional mat, in particular to a practical and breathable three-dimensional mat.

Mat materials have become one of the indispensable items in life. For example, when people perform yoga exercises, they will use yoga mats to avoid direct human body contact with the ground; when people sit on seats, they will use seat cushions or back cushions to avoid direct human body contact. Seats; when people lie in bed, they use mattresses to prevent direct contact with the bed frame.

However, most of the commonly used mattress materials are not breathable. When in contact with the human body for a long time, the heat emitted by the human body cannot be discharged and will become stuffy inside the mattress material. After long-term use, it is easy to produce odor and breed bacteria.

Based on the above shortcomings, the purpose of the present invention is to provide a three-dimensional cushion material, especially a three-dimensional cushion material that is practical and breathable.

According to the object of the present invention, a three-dimensional mat is provided, which includes a base layer, a front surface of the base layer is formed by a composite mesh, and the front surface of the base layer has a plurality of protrusions arranged in a matrix.

The composite mesh material has at least two mesh bodies stacked on top of each other, so that there is at least one step portion between the bottom surface and the top surface of each raised portion, and each mesh body has a plurality of mesh holes arranged in a matrix.

The at least two mesh bodies include a first mesh body disposed close to the bottom surface of the base layer, a second mesh body disposed on a surface of the first mesh body away from the base layer, and the first mesh body The aperture of the mesh is larger than the aperture of the meshes of the second mesh body.

Each of the protrusions has a protrusion height, and the protrusion heights of the plurality of protrusions in each row of the protrusions gradually increase or decrease toward the first direction.

At least a part of the protruding portions has a cutout on a top surface thereof.

The base layer is a single-layer structure or a multi-layer structure made of elastomer or/and diatomaceous earth.

There is an internal space between the bottom surface and the top surface of each protrusion.

The invention also provides a method for manufacturing a three-dimensional mat, which includes the following steps: S1: heating and softening a base layer at a temperature of 150°C to 200°C; and S2: placing a composite mesh on a front side of the base layer, The composite mesh has a plurality of meshes arranged in a matrix. A forming force is applied to the base layer or the composite mesh to deform the base layer toward the composite mesh, so that the base layer forms a plurality of meshes arranged in a matrix. a convex part.

Preferably, the manufacturing method of the three-dimensional cushion material may also include a step: S3: cutting off the top surface of at least part of the protrusions to form an incision.

Wherein the forming force is at least one of gas pressure or vacuum suction or temperature difference pressure or using a pressurized sheet or filled with high-density material or filled with foamed material.

X: first direction

h,h1~h6: convex height

S1~S3: steps

d1, d2: aperture

10: Basal layer

11:Protruding part

11a:Top surface

11b: Bottom surface

11c: Step part

13: Incision

20: Composite mesh material

21:First network body

21a: Mesh

22:Second mesh body

22a: Mesh

Figure 1 is an exploded view of components of the three-dimensional cushion material of the present invention.

Figure 2 is a schematic diagram of the first embodiment of the three-dimensional cushion material of the present invention.

Figure 3 is a cross-sectional view of the protruding portion of the three-dimensional cushion material of the present invention.

Figure 4 is a schematic diagram of the second embodiment of the three-dimensional cushion material of the present invention.

Figure 5 is a cross-sectional view of the protruding portion of the third embodiment of the three-dimensional cushion material of the present invention.

Figure 6 is a flow chart of the manufacturing method of the three-dimensional mat material of the present invention.

In order to clearly illustrate the specific implementation, structure and achieved effects of the present invention, examples are provided and described with drawings as follows: Please refer to Figures 1 to 2, which illustrate a three-dimensional mat, including a base layer 10, a composite The net material 20 forms a front surface of the base layer 10. The composite net material 20 has at least two net bodies (the first net body 21 and the second net body 22) stacked on each other. Each of the net bodies 21 and 22 has a shape of A plurality of meshes 21a, 22a arranged in a matrix, the at least two mesh bodies 21, 22 include a first mesh body 21 disposed close to the front surface of the base layer 10, and a second mesh body 22 disposed on the first mesh body 21 is far away from a surface of the base layer 10. The pore diameter d1 of the mesh holes 21a of the first mesh body 21 is larger than the pore diameter d2 of the mesh holes 22a of the second mesh body 22. The composite mesh material 20 is subjected to A forming force causes the composite mesh 20 to be pressed toward the base layer 10 so that the base layer 10 forms a plurality of protrusions 11 arranged in a matrix. Or, you can The forming force is applied to a surface of the base layer 10 opposite to the composite mesh 20 to cause the base layer 10 to protrude toward the composite mesh 20 to form the protrusions 11 . The base layer 10 is a single-layer structure or a multi-layer structure made of elastomer or diatomite. It can be composed of a single layer of elastomer and a single layer of diatomite, or a multi-layer elastomer or multi-layer diatomite, or a multi-layer elastomer and Composed of multiple layers of diatomaceous earth. The aforementioned elastomer may be a thermoplastic elastomer or a thermosetting elastomer. The composite mesh 20 is made of stable material, and can be a steel mesh or a cloth mesh. In other embodiments, the composite mesh 20 can also be made of other hard materials.

Please refer to Figure 3. In the first embodiment of the present invention, there is at least one step portion 11c between the bottom surface 11b and the top surface 11a of each raised portion 11, so that the outline of the raised portion 11 is trapezoidal. The protruding portion 11 contacts the human body to produce massage and stimulation of acupuncture points. In other embodiments, the composite mesh 20 may be formed by stacking three or more mesh bodies, so that two or more meshes are formed between the bottom surface 11b and the top surface 11a of the protruding part 11. The step portion 11c. In addition, there is an internal space between the bottom surface 11b and the top surface 11a of the raised portion 11 . In the first embodiment, the protruding height h of each protruding part 11 of the protruding parts 11 is equal (the protruding height h is defined as the distance between the bottom surface 11b and the top surface 11a of the protruding part 11) .

It is worth mentioning that when the bottom surface of the base layer 10 is laid on the ground or the surface of other objects, the internal spaces of the raised portions 11 can be used as air receiving spaces, so that the raised portions 11 provide air bags. buffering effect.

Please refer to Figure 4. In the second embodiment of the present invention, a cutout 13 is formed on the top surface 11a of at least a part of the protruding portions 11. The cutout 13 serves as an inlet and outlet for air flow, increasing the The breathability of the three-dimensional mat prevents the breeding of bacteria due to moisture and heat in the three-dimensional mat. In addition, the convex The three-dimensional structure of the raised portion 11 can also prevent the liquid flowing into the cushion material from overflowing upward in the air chamber formed by the three-dimensional cushion material, thereby increasing the convenience of use.

Please refer to Figure 5. In the third embodiment of the present invention, the three-dimensional cushion material can be used for seat cushions, mattresses, insoles, floor mats, yoga mats, game mats or foot mats, and can be adjusted according to user needs. The strength of the forming force exerted by the composite mesh 20 and the height h1, h2, h3, h4, h5, h6 of each of the plurality of protrusions 11 in each row of the protrusions 11 are directed towards the third One direction X gradually decreases (the protrusion heights h1, h2, h3, h4, h5, h6 are defined as the distance between the bottom surface 11b and the top surface 11a of the protrusion 11) to achieve more diverse usage methods. In other embodiments, each protrusion height h1, h2, h3, h4, h5, h6 of the plurality of protrusions 11 in each row of the protrusions 11 gradually increases toward the first direction X.

In other embodiments, light-emitting elements or electronic components can also be provided in the three-dimensional mat. The electronic components are vibration components or sound components, thereby increasing the practicality of the three-dimensional mat. Furthermore, a waterproof layer can also be coated on the surface of the three-dimensional mat to reduce moisture from entering the interior of the three-dimensional mat to achieve a waterproof effect.

Please refer to Figure 6. The present invention also provides a method for making a three-dimensional mat, which includes the following steps: S1: heating and softening a base layer 10 at a temperature of 150°C to 200°C; S2: placing a composite mesh 20 on the base layer 10. On a front side of the base layer 10, the composite mesh 20 has a plurality of mesh holes 21a, 22a arranged in a matrix. A forming force is applied to the base layer 10 or the composite mesh 20 to make the base layer 10 face the composite mesh. The material 20 is deformed, so that the base layer 10 forms a plurality of protrusions 11 arranged in a matrix; and S3: cutting off the top surface 11a of at least part of the protrusions 11 to form an incision 13.

To further explain, the forming force is at least one of gas pressure, vacuum suction, temperature difference pressure, or using a pressurized sheet, filling with high-density materials, or filling with foaming materials.

To further explain, the composite mesh 20 is detachable, and the composite mesh 20 can be disassembled after the protruding portion 11 is formed to prevent human body from being injured due to contact with hard materials. Alternatively, the composite net material 20 can be combined with the base layer 10 so that the base layer 10 covers the composite net material 20 and the composite net material 20 cannot be disassembled. Since the base layer 10 is combined with the composite net material 20, Even if it comes into contact with the human body, it will not cause harm to the human body.

d1, d2: aperture

10: Basal layer

20: Composite mesh material

21:First network body

21a: Mesh

22:Second mesh body

22a: Mesh

Claims (10)

A three-dimensional mat, including a base layer, a front surface of the base layer formed by a composite mesh, the front surface of the base layer having a plurality of convex portions arranged in a matrix, the bottom and top of each convex portion There is an internal space between the faces. The three-dimensional mat according to claim 1, wherein the composite mesh material has at least two mesh bodies stacked on top of each other, so that there is at least one step portion between the bottom surface and the top surface of each raised portion, and each mesh body is The body has a plurality of meshes arranged in a matrix. The three-dimensional mat according to claim 2, wherein the at least two mesh bodies include a first mesh body disposed close to the front surface of the base layer, and a second mesh body disposed on the first mesh body away from the base layer. On one surface, the apertures of the meshes of the first mesh body are larger than the apertures of the meshes of the second mesh body. The three-dimensional mat as claimed in claim 1, wherein each of the protruding parts has a protruding height, and each of the protruding heights of the plurality of protruding parts on each row of the protruding parts is directed toward the first The direction gradually increases or decreases. The three-dimensional mat according to claim 1, wherein at least a part of the protruding portions has a cutout on the top surface thereof. The three-dimensional mat as claimed in claim 1, wherein the base layer is a single-layer structure made of elastomer or diatomaceous earth. The three-dimensional mat as claimed in claim 1, wherein the base layer is a multi-layer structure made of elastomer and diatomaceous earth. A method of manufacturing a three-dimensional mat as described in claim 1, comprising the following steps: S1: A base layer is heated and softened at a temperature of 150°C to 200°C; and S2: A composite mesh is provided on a front side of the base layer. The composite mesh has a plurality of meshes arranged in a matrix. The layer or the composite mesh applies a forming force to cause the base layer to deform toward the composite mesh, so that the base layer forms a plurality of protrusions arranged in a matrix. The method of manufacturing a three-dimensional mat as claimed in claim 8 may further include a step: S3: cutting off the top surface of at least part of the protrusions to form an incision. The method for manufacturing a three-dimensional mat according to claim 8, wherein the forming force is at least one of gas pressure, vacuum suction, temperature difference pressure, or using a pressurized sheet, filling with high-density materials, or filling with foaming materials.

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