TWI815610B - Mat and method for manufacturing the same - Google Patents

Abstract

A mat and a method for manufacturing the same are provided, the mat including: a first foam layer, having a first hardness and a first porosity; a second foam layer, connected with a side of the first foam layer, having a second hardness and a second porosity larger than the first porosity; and a third foam layer, connected with a side of the second foam layer opposite to the first foam layer, having a third hardness which is larger than the first hardness and the second hardness and a third porosity smaller than the first porosity; wherein the second foam layer includes a first connecting surface facing the first foam layer and a second connecting surface facing the third foam layer, and a contact area of the first connecting surface and the first foam layer is different from a contact area of the second connecting surface and the third foam layer.

Description

Pad body and its preparation method

The present invention relates to a cushion body, and in particular to a cushion body and a manufacturing method thereof.

Conventional mats are used for different purposes, such as but not limited to being used as yoga mats, game mats, anti-slip mats, etc. The materials and foaming levels are generally matched to meet various functional requirements. In order to increase the thickness or other usage requirements, the conventional cushion system is made by bonding multiple layers to each other with colloids. For example, an anti-slip layer is bonded to one side of a foam layer so that one surface of the cushion body has anti-slip properties. Sliding effect.

However, it is known that the colloid easily produces odor, resulting in poor user experience, and the manufacturing process of the pad body is complicated, resulting in high manufacturing costs. In addition, due to the difference in properties between the adjacent two-layer body and the colloid, it is easy to raise concerns about insufficient bonding strength, and the joint surface of the two-layer body may also cause the local hardness or compressibility of the cushion body due to the colloid. It cannot meet expectations and there are shortcomings that need to be improved urgently.

Therefore, it is necessary to provide a novel and progressive cushion body and a manufacturing method thereof to solve the above problems.

The main purpose of the present invention is to provide a pad body and a manufacturing method thereof that are odorless, easy to manufacture and have diversified functions.

In order to achieve the above object, the present invention provides a cushion body, including: a first foam layer having a first hardness and a first porosity; a second foam layer connected to one of the first foam layers side, having a second hardness not greater than the first hardness and a second porosity greater than the first porosity; and a third foam layer connected to the second foam layer relative to the first foam layer One side of the foam layer has a third hardness greater than the first hardness and a third porosity less than the first porosity; wherein the second foam layer includes a third surface facing the first foam layer. A joint surface and a second joint surface facing the third foam layer. The contact area of the first joint surface and the first foam layer is different from the contact area of the second joint surface and the third foam layer. area.

In order to achieve the above object, the present invention further provides a method for manufacturing the cushion body as described above, which includes the following steps: foaming and molding the first foam layer, the second foam layer and the third foam layer; and thermocompression bonding. One of the first foam layer and the third foam layer is bonded to the second foam layer; the other of the first foam layer and the third foam layer is heat-pressed and bonded to the second foam layer. To form a base material; and cut the base material to form at least one of the pad bodies.

1: Pad body

10: First foaming layer

11: Color block

12: Embossed structure

20: Second foam layer

21: First joint surface

22: Second joint surface

23:Middle part

24:hole

30: The third foaming layer

31: Contact surface

311:The first groove

312:Second groove

313:Unit 1

314:Unit 2

40: Group connection structure

S1~S4: steps

Figure 1 is a perspective view of a preferred embodiment of the present invention.

Figure 2 is an exploded view of a preferred embodiment of the present invention.

Figure 3 is another exploded view of a preferred embodiment of the present invention.

Figure 4 is a partial enlarged view of a preferred embodiment of the present invention.

Figure 5 is a partial enlarged view of Figure 1.

Figure 6 is a schematic diagram of a preferred embodiment of the present invention.

Figure 7 is a step flow chart of a preferred embodiment of the present invention.

The following examples are only used to illustrate the possible implementation modes of the present invention, but are not intended to limit the scope of protection of the present invention.

Please refer to Figures 1 to 7, which show a preferred embodiment of the present invention. The cushion body 1 of the present invention includes a first foam layer 10, a second foam layer 20 and a third foam layer 30.

The first foam layer 10 has a first hardness and a first porosity; the second foam layer 20 is connected to one side of the first foam layer 10 and has a second hardness and a greater than the first porosity. The second porosity of the porosity; the third foaming layer 30 is connected to one side of the second foaming layer 20 relative to the first foaming layer 10 and has a greater than the first hardness and the second hardness. A third hardness and a third porosity less than the first porosity; wherein, the second foaming layer 20 includes a first joint surface 21 facing the first foaming layer 10 and a third foaming surface 21 facing the first foaming layer 10 . The contact area of the second joint surface 22 of the layer 30 and the first joint surface 21 and the first foam layer 10 is different from the contact area of the second joint surface 22 and the third foam layer 30 . Thereby, the first foam layer 10 and the third foam layer 30 have different softness and hardness and can be selected according to needs, with diversified functions, and the second foam layer 20 can provide good cushioning and shock-absorbing effects. .

The first hardness, the second hardness and the third hardness refer to the average hardness of the first foam layer 10, the second foam layer 20 and the third foam layer 30 respectively. In this embodiment, measured with a C-type hardness meter, the numerical range of the first hardness is between 20 and 35; the numerical range of the second hardness is between 20 and 35; the numerical value of the third hardness is greater than 40; where The C-type hardness tester, for example, is the TECLOCK C-type hardness tester (GS-701N), which is based on the SRIS standard and can be used to test the hardness of sponges, soft rubber, and foams with a hardness less than Type A 20. The larger the test value, the harder the hardness. big. When measuring the hardness, the measurement has been combined into For example, the first hardness of the cushion body 1 is about 30, and the measurement position is a surface of the first foam layer 10 facing away from the second foam layer 20. The first foam layer 10 is relatively soft and easy to deform under pressure, and can be used as a yoga mat, with comfortable touch and good cushioning effect; the third hardness is about 50, and its measurement position is when the third foam layer 30 faces away from the second foam On one surface of the layer 20, the third foam layer 30 has a relatively large hardness and is not easily deformed when pressed. It can be used to place heavy objects (such as fitness equipment, machines, etc.) to provide shock absorption and good stability; The second hardness is about 20, and its measurement position is the portion of the second foam layer 20 exposed outward on a cut surface of the cushion body 1 . In detail, the second foam layer 20 further includes an intermediate portion 23 between the first joint surface 21 and the second joint surface 22. At least one of the first joint surface 21 and the second joint surface 22 is The hardness is greater than the hardness of the middle portion 23 , thereby stably bonding with the first foam layer 10 and the second foam layer 20 . In this embodiment, the cushion body is provided with a joint structure 40 around 1 side, whereby it can be spliced to each other to suit different use areas. The first foam layer 10 can also face upward or the third foam layer 30 can face upward. Spliced in a way to distinguish the use area (as shown in Figure 6), such as the freehand exercise area or the equipment area, the layout is diverse and convenient.

Due to the difference in hardness of the first foam layer 10 and the third foam layer 30, when they are subjected to the same amount of pressure, the deformation range of the first foam layer 10 is deeper and narrower, and the deformation range of the third foam layer 30 is deeper and narrower. The deformation range of layer 30 is shallower and wider. Referring to FIG. 4 , the contact area between the first joint surface 21 and the first foam layer 10 is larger than the contact area between the second joint surface 22 and the third foam layer 30 ; the second foam layer 20 is adjacent to The density of one side of the first joint surface 21 is greater than the density of one side of the second foam layer 20 adjacent to the second joint surface 22 , whereby the first joint surface 21 can conform to the first foam layer 10 It is deformed by force and has good adhesion, and the second foam layer 20 can be compressed to reduce the hardness difference. The second foam layer 20 includes a plurality of closed holes 24, and the plurality of holes 24 are at least partially open to the third foam layer 30 on the second joint surface 22, whereby when the third foam layer 30 is subjected to When pressed, the second foam layer 20 can be compressed and deformed by the plurality of holes 24, and the deformation margin is sufficient to prevent mutual peeling due to excessive hardness differences. At the same time, local dents can be avoided and the supportability is good.

The thickness of the second foam layer 20 is not less than the thickness of the first foam layer 10 and less than the thickness of the third foam layer 30 . In detail, the thickness of the third foam layer 30 is at least twice the thickness of the second foam layer 20, which has good stability and shock absorption effect during use; the thickness of the second foam layer 20 is At least twice the thickness of a foam layer 10, the buffering effect is good. However, the thicknesses of the first foam layer, the second foam layer and the third foam layer can also be adjusted according to needs.

In this embodiment, the materials of the first foam layer 10 and the third foam layer 30 include polyethylene (PE) and ethylene vinyl acetate copolymer (EVA). The PE content of the first foam layer 10 is less than the PE content of the third foam layer 30 , thereby generating foam structures with different hardnesses; the EVA content of the first foam layer 10 is greater than the EVA of the third foam layer 30 content, whereby the first foam layer 10 can provide excellent anti-slip effect; the material of the second foam layer 20 includes PE, which is easy to adjust the hardness and thickness, has good resilience and is light weight. It should be noted that when the third foam layer 30 faces upward and the first foam layer 10 contacts a placement surface, the first foam layer 10 can provide better protection when the cushion body 1 is stressed. Excellent anti-slip effect; for example, when placing fitness equipment on the third foam layer 30, since the pad body 1 bears the weight of the equipment and increases the downward pressure, the space between the first foam layer 10 and the placement surface The friction force is increased and it is not easy to move due to force, and the safety is good. Preferably, the first foam layer 10 and the third foam layer 30 are closed foam structures, which are not easily deformed and have good waterproof effect; the melting point of the second foam layer 20 is lower than that of the first foam layer. The melting points of the first foam layer 10 and the third foam layer 30 can be combined with the first foam layer 10 and the third foam layer 30 by heating and melting the first joint surface 21 and the second joint surface 22 during processing. The foam layers 30 are adhered to each other without the use of adhesives and can prevent the structures of the first foam layer 10 and the third foam layer 30 from being changed by heating, resulting in good processing stability. Inorganic fillers (such as calcium carbonate) can also be added to the first foam layer 10 , the second foam layer 20 and the third foam layer 30 to increase processing stability. In other embodiments, The first foaming layer, the second foaming layer and the third foaming layer can also be made of other materials according to needs, or dyes, plasticizers, etc. can be added.

The first foam layer 10 includes a plurality of color blocks 11. The plurality of color blocks 11 include at least two different colors and are mixed and embedded with each other to provide special visual effects and good aesthetics. The first foam layer 10 is provided with an embossed structure 12 on one surface relative to the second foam layer 20, which has good anti-slip effect and good touch feeling. In other embodiments, the first foaming layer may also be composed of sheets of a single color. Referring to FIG. 5 , the third foam layer 30 includes a contact surface 31 relative to the second foam layer 20 . The contact surface 31 is provided with a plurality of first grooves 311 and a plurality of second grooves 312 extending in a curved manner. , the plurality of first grooves 311 extend at least partially transversely to the plurality of second grooves 312; the plurality of first grooves 311 are arranged side by side to form a plurality of first units 313, and the plurality of second grooves 312 are arranged side by side to form a plurality of second units 313. Units 314, the plurality of first units 313 and the plurality of second units 314 are arranged in a staggered manner, which has good anti-slip effect and aesthetics. However, the plurality of first grooves and the plurality of second grooves can also be configured in a wavy shape, a polygonal shape, a geometric structure, etc.

The present invention also provides a method for manufacturing the cushion body 1 as described above, which includes the following steps. Step S1: Foam forming the first foam layer 10, the second foam layer 20 and the third foam layer 30; Step S2: Thermocompression bonding the first foam layer 10 and the third foam layer One of 30 and the second foam layer 20; Step S3: Heat-press and bond the other of the first foam layer 10 and the third foam layer 30 to the second foam layer 20 to form a base material ; and step S4: Cut the base material to form at least one pad body 1.

The foaming in step S1 to form the first foam layer 10 also includes the following steps: preparing a mold; placing a plurality of raw material particles in the mold, wherein the plurality of raw material particles include at least two different colors, the The plurality of raw material particles include, for example, PE resin particles and EVA resin particles; the plurality of raw material particles are heated and melted and foamed into a foam; and the foam is taken out from the mold and cut into at least one first layer according to a predetermined thickness. Foam layer 10. In this way, multiple layers of the third layer can be obtained with only a single foaming operation. A foam layer 10 is easy to manufacture and has a dense foam structure, good waterproofness and wear resistance, and the plurality of color blocks 11 are randomly arranged to form a unique appearance.

In this embodiment, the second foam layer 20 is continuously foamed to form the plurality of holes 24 with larger sizes, and the foam structure of the second foam layer 20 is relatively fluffy and has good compressibility; The third foam layer 30 is molded and foamed to have a dense foam structure with high hardness, good waterproofness and wear resistance; the second foam layer 20 is first joined to the first foam layer 10 Finally, the third foam layer 30 is joined to the side of the second foam layer 20 opposite to the first foam layer 10 . For example, in step S2, the first foam layer 10 can be first aligned with the first joint surface 21, and a heating mechanism (such as a hot air gun) is used to heat and melt the first joint surface 21, and then the first joint surface 21 can be heated and melted. The first foam layer 10 and the second foam layer 20 are pressed together through a rolling mechanism at the same time. Since the first foam layer 10 and the second foam layer 20 have better flexibility, they are combined It can still be rolled up to facilitate subsequent operations; similarly, in step S3, the third foam layer 30 can be aligned with the second joint surface 22 first, and the second joint surface 22 can be heated and melted by the heating mechanism. , and then pass the third foam layer 30 and the combined first foam layer 10 and the second foam layer 20 through the rolling mechanism at the same time to form the base material. In other embodiments, the second foam layer can also be joined to the third foam layer first, and then to the first foam layer; the first foam layer or the third foam layer can also be heated and melted. The layers are fused to each other with the first joint surface or the second joint surface.

1: Pad body

31: Contact surface

40: Group connection structure

Claims (13)

A cushion body, including: a first foam layer having a first hardness and a first porosity; a second foam layer connected to one side of the first foam layer and having a second hardness and a first porosity. a second porosity greater than the first porosity; and a third foam layer, connected to a side of the second foam layer opposite to the first foam layer, having a hardness greater than the first and the first foam layer. The third hardness of the second hardness and the third porosity less than the first porosity; wherein, the second foam layer includes a first joint surface facing the first foam layer and a first joint surface facing the third foam layer. The second joint surface of the foam layer, the contact area of the first joint surface and the first foam layer is different from the contact area of the second joint surface and the third foam layer; wherein, the second foam layer It also includes a middle portion between the first joint surface and the second joint surface, and the hardness of at least one of the first joint surface and the second joint surface is greater than the hardness of the middle portion. The cushion body according to claim 1, wherein the contact area between the first joint surface and the first foam layer is greater than the contact area between the second joint surface and the third foam layer. The pad of claim 1, wherein the density of the second foam layer adjacent to the first joint surface is greater than the density of the second foam layer adjacent to the second joint surface. The cushion body according to claim 1, wherein the thickness of the second foam layer is not less than the thickness of the first foam layer and less than the thickness of the third foam layer. The cushion body according to claim 4, wherein the thickness of the third foam layer is at least twice the thickness of the second foam layer. The cushion body according to claim 1, wherein the first foam layer includes a plurality of color blocks, and the plurality of color blocks include at least two different colors and are mixedly embedded with each other. The cushion body according to claim 1, wherein the third foam layer includes a contact surface relative to the second foam layer, and the contact surface is provided with a plurality of first grooves and a plurality of second grooves that extend in a curved manner. , the first plurality of grooves extend at least partially transversely to the plurality of second grooves. The cushion body according to claim 5, wherein the first foam layer and the third foam layer are both made of polyethylene (PE) and ethylene vinyl acetate copolymer (EVA). , the PE content of the first foaming layer is less than the PE content of the third foaming layer; the material of the second foaming layer includes PE; the EVA content of the first foaming layer is greater than the EVA of the third foaming layer content; the material of the second foam layer includes PE; the thickness of the second foam layer is at least twice the thickness of the first foam layer; the contact area between the first joint surface and the first foam layer Greater than the contact area between the second joint surface and the third foam layer; the density of the second foam layer adjacent to the first joint surface is greater than the density of the second foam layer adjacent to the second joint surface The density on one side; the first foam layer and the third foam layer are both closed foam structures; the melting point of the second foam layer is lower than that of the first foam layer and the third foam layer Melting point; measured with a C-type hardness meter, the numerical range of the first hardness is between 20 and 35; the numerical range of the second hardness is between 20 and 35; the numerical value of the third hardness is greater than 40; the first foaming The layer includes a plurality of color blocks, and the plurality of color blocks include at least two different colors and are mixed with each other; the third foam layer includes a contact surface relative to the second foam layer, and the contact surface is provided with A plurality of first grooves and a plurality of second grooves are curved and extended, and the plurality of first grooves at least partially extend transversely to the plurality of second grooves; the plurality of first grooves are arranged side by side to form a plurality of first units, and the plurality of first grooves are arranged side by side to form a plurality of first units. The two grooves are arranged side by side to form a plurality of second units, the plurality of first units and the plurality of second units are staggered with each other; and the first foam layer is provided with an embossed structure relative to a surface of the second foam layer. A method for manufacturing the cushion body according to any one of claims 1 to 8, including the following steps: foaming and molding the first foam layer, the second foam layer and the third foam layer; One of the first foam layer and the third foam layer is thermo-compression bonded to the second foam layer; the other of the first foam layer and the third foam layer is thermo-compression bonded to the second foam layer. Foaming the layer to form a base material; and cutting the base material to form at least one pad body. The method of claim 9, wherein the step of foaming to form the first foam layer further includes the following steps: preparing a mold; placing a plurality of raw material particles in the mold, wherein the plurality of raw material particles include at least two different colors; heat and melt the plurality of raw material particles and foam them into a foam; and take out the foam from the mold and cut it into at least one first foam layer according to a predetermined thickness. The manufacturing method as claimed in claim 9, wherein the second foaming layer is continuously foamed and formed. The manufacturing method as claimed in claim 9, wherein the third foaming layer is molded and foamed. The manufacturing method of claim 9, wherein the second foam layer is first joined to the first foam layer, and then the third foam layer is joined to the second foam layer relative to the first foam layer. One side of the bubble layer.

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