KR102174441B1 - Method of manufacturing mat for child-rearing using fabric as an intermediate core material - Google Patents

Abstract

The present invention relates to a method for manufacturing a mat for child-rearing using a fabric used as an intermediate core material for laying on the floor of a home or a children's playroom, and the mat is damaged by a sharp awl or a knife using a fabric as an intermediate core material, This is to make it possible to produce a new type of mat that prevents stickiness due to the limitation of the physical properties of synthetic resin and prevents noise due to friction.
To this end, the present invention solidifies the TPU by supplying a liquid TPU 150 to the upper surface of the printing layer 111 while supplying a fabric 110 having a print layer 111 formed on the surface and having a predetermined width. Forming the surface layer 112 having a thickness of 50 μm to 100 μm, and transferring the fabric 110 and PU sponge 210 on which the surface layer 112 is formed, respectively, After supplying TPU to form the TPU layer 151, heat is applied while passing between the heating pressing roller 251 and the silicon roller 252 to obtain a semi-finished product 270, and the semi-finished product 270 is formed on both sides. Applying the liquid TPU 150 to the adhesive surface of the PU sponge 210 while supplying from, then applying heat while passing the heating pressing roller 351 and the silicone roller 352 to laminate them, and the laminated mat ( It characterized in that it comprises the step of cutting 370) to a predetermined size and finishing the edge of the mat cut to the predetermined size.

Description

Manufacturing method of mat for parenting using fabric as an intermediate core material{omitted}

The present invention relates to a method of manufacturing a mat for infants used on the floor of a home or a children's playroom, and more specifically, the mat is damaged by a sharp awl or a knife using a fabric as an intermediate core material, or It relates to a method of manufacturing a mat for child-rearing using a fabric that can produce a new type of mat that prevents stickiness due to the limitation of physical properties and prevents noise due to friction.

In general, mats have a function to allow infants to play in a safe state by laying them on the floor of a home's living room, baby's room, or playroom facility.

As a material of such a mat, polyethylene foam (PE: non-crosslinked, crosslinked), polyvinyl chloride foam (PVC), or appropriately laminated these mats has been produced.

Polyethylene (PE) used as the material of the mat is a translucent thermoplastic material, and the surface layer is often processed into a transparent thin film, and the thick foam cross section is shaped like a translucent foam sponge.

However, if you use colorants, you can not only obtain products of various colors, but also have low cost, excellent toughness at room temperature, sufficient strength even at low temperatures, flexibility up to -73℃, corrosion resistance and excellent insulation, odorless, tasteless, and low water. -It has many important properties in terms of industry, such as vapor permeability.

On the other hand, polyvinyl chloride (PVC) is the second most widely used synthetic plastic, and the use of polyvinyl chloride is mainly due to its unique ability to make compounds having various physical and chemical properties by mixing additives with high chemical resistance. Originated.

Such polyvinyl chloride is difficult to process and has low impact strength, and by adding a silicone resin, the fluidity of the melt during processing can be improved.

The silicone material added to the polyvinyl chloride absorbs and disperses the impact energy by increasing the impact resistance of the material, thereby alleviating the phenomenon of injury to infants.

However, although the conventional mat made only of polyethylene has the advantage of being inexpensive, several problems have occurred as follows.

First, since the printing film is directly or indirectly thermally fused on the surface, it deteriorates when used for a long time and the film peels off.

Second, because the material is light, the mat does not stably adhere to the floor and slides well, and the mat flies well even in a weak wind, so it is inconvenient to use.

Third, in the mat, cushion and touch are important factors as they are the criteria for judging the quality of the product. Since the cushion and touch are not good due to weak resilience, there is a limit to absorbing shock when an infant falls, and there is a risk of injury.

Fourth, since high-frequency fusion is not possible during the finishing work of the rim part, not only the rim part cannot be cleanly finished due to thermal fusion or separate sewing work, and the work is cumbersome.

On the other hand, polyvinyl chloride solves the problems of polyethylene to some extent, but this also has the following problems.

First, the material was so heavy that it was difficult for housewives to carry the mat.

Second, the high cost of materials has acted as a factor in increasing production costs.

Third, it is harmful to the human body of infants because polyvinyl chloride is produced using a plastic material called phthalate that releases environmental hormones.

Due to the above problems, recently, a mat is produced by laminating polyethylene on the upper surface of polyvinyl chloride having a predetermined thickness.

1 is a perspective view of a conventional mat, FIG. 2 is a cross-sectional view taken along line AA of FIG. 1, and FIG. 3 is a state diagram showing a laminating process of the conventional mat. The mat 100 is an upper mat 10 manufactured by foam molding polyethylene (PE). ), and a lower mat 20 manufactured by foam molding polyvinyl chloride (PVC), and an aqueous adhesive 30 is applied to the upper end of the lower mat 20 so that the upper mat 10 becomes the lower mat 20 It is laminated to, and is composed of a frame 40 that is sewn along the edges of the laminated upper mat 10 and the lower mat 20 and treated with hem.

The mat 100 is a household product that is widely used in a home living room or a playroom for infants, and is mainly made of synthetic resin, among which polyethylene (PE) and polyvinyl chloride (PVC) are widely used.

The upper mat 10 is manufactured by foam molding a polyethylene resin, and a printing layer 50 is provided over the entire upper surface, and the upper surface of the upper mat 10 has uneven embossing protrusions to prevent slipping. Can be formed.

The polyethylene (PE) is a synthetic resin that can reduce the cost of the mat and reduce the weight of the mat due to its low cost and light characteristics, and the mat made of polyvinyl chloride (PVC) is harmless to the human body so that the infant's body comes into contact with it. It can be used safely.

The printing layer 50 is painted over the entire upper surface of the upper mat 10 and various pictures are printed. The printing layer 50 is formed by attaching a sticker or coating. It is selectable and can be produced in a variety of colors and designs, so you can draw from designs for children in the playroom to illustrations or artworks.

The lower mat 20 is manufactured by foaming polyvinyl chloride, and the polyvinyl chloride has good resilience and good cushioning and touch, and is not pushed due to its weight, so it is widely used as a material for high-quality mats.

The water-based adhesive 30 is formed in a semi-dry state by applying an adhesive pigment over the entire upper surface of the lower mat 20 manufactured by foam molding polyvinyl chloride (PVC) and heating it at 60°C to 80°C. do.

The aqueous pressure-sensitive adhesive 30 is a medium that allows the upper mat 10 and the lower mat 20 to be laminated, and integrates the upper mat 10 and the lower mat 20.

As shown in FIG. 3, the upper mat 10 and the lower mat 20 are pressed and laminated while passing the upper mat 10 and the lower mat 20 to the roller R, and the upper mat 10 And the lower mat 20 can be detached and attached by the adhesive force of the aqueous adhesive 30.

By forming the mat 100 by laminating polyethylene and polyvinyl chloride as described above, the advantages of polyethylene are saved, but the disadvantages are compensated, and the advantages of polyvinyl chloride are preserved, but by supplementing the disadvantages, a mat having only the advantages of polyethylene and polyvinyl chloride. Is obtained.

The conventional mat is composed of an upper mat (10) and a lower mat (20), and then sewn along the edges of the upper mat (10) and the lower mat (20), and then treated with a hem 40. 10) and the lower mat 20 are firmly fixed and not separated.

Here, the binding is a post-sewing treatment technology in which the lining material is cut with a bias to clean the seam allowance, and the seam allowance is padded and sewn neatly.

As described above, when the upper mat 10 and the lower mat 20 are laminated and then formed with a hem treatment, when the mat 100 has reached the end of its life and must be discarded, the sewing part of the hem 40 treated with the hem And the upper mat 10 and the lower mat 20 are removed, so they can be separated.

Korean Patent Application Publication No. 10-2011-0121058 (published on November 7, 2011) Republic of Korea Utility Model Publication No. 20-0416915 (registered on May 15, 2006) Registered Korean Patent Publication No. 10-1563106 (registered on October 19, 2015) Registered Korean Patent Publication No. 10-1767871 (registered on Aug. 7, 2017)

However, the conventional mat having such a structure has several problems as follows.

First, since the upper mat is made of polyethylene resin and the lower mat is made of polyvinyl chloride, the mat is easily torn or damaged by a sharp awl or knife, resulting in shortened lifespan.

Second, when walking on the mat due to the limitation of the material properties of synthetic resin, it was sticky or noise was generated by friction.

Third, since polyvinyl chloride (PVC) is produced using a plastic material called phthalate, it is harmful to the human body of infants.

Fourth, when the mat is used for a long period of time, the picture or pattern transferred to the upper surface of the upper mat made of polyethylene is peeled off due to the peeling of the film, and the transferred print layer is whitened, causing the print layer to solidify and bury it on the human body. For the purpose of preventing this, a separate film must be formed on the surface of the printing layer or a receiving coating process must be performed, which has acted as a factor of increasing production cost.

The present invention has been devised to solve such a problem in the related art, and a PU sponge coated with a thermal polyurethane (hereinafter referred to as "TPU") so that the fabric is positioned on the upper and lower parts of the mat. The purpose is to prevent the mat from being damaged by sharp awls or knives by combining them with.

Another object of the present invention is to form a surface layer coated with TPU at a predetermined thickness on the top and bottom of the mat so that it is not sticky or noise is generated when walking the mat.

According to an aspect of the present invention for achieving the above object, a printed layer is formed on the surface and a liquid TPU is supplied to the upper surface of the printed layer while supplying a fabric having a predetermined width to solidify the TPU to 50 μm to 100 μm. Forming a thick surface layer, and supplying a liquid TPU having a higher viscosity than the surface layer to the adhesive surface while transferring the fabric and PU sponge with the surface layer formed thereon to form a TPU layer, and then between the heating and pressing roller and the silicone roller. The steps of obtaining a semi-finished product by applying heat while passing through it, and applying the liquid TPU to the adhesive surface of the PU sponge while supplying the semi-finished product from both sides, and then applying heat while passing through a heating press roller and a silicone roller to laminate them. , There is provided a method for manufacturing a mat for child-rearing using a fabric as an intermediate core material, comprising the step of cutting the laminated mat into a predetermined size and finishing the edge of the mat cut into a predetermined size.

The present invention has several advantages compared to the prior art.

First, since the fabric is adhered to both sides of the PU sponge so that it is located at the top and bottom of the mat, it prevents the mat from being easily torn or damaged by a sharp awl or a knife, so the service life of the mat can be extended. There will be.

Second, since the top and bottom of the mat is provided with a surface layer coated with TPU with low viscosity, it is possible to reduce the friction noise when walking the mat as well as stickiness since it is soft and expects a surface strengthening effect.

Third, it is eco-friendly because TPU, which is harmless to infants, is exposed to the outside of the mat.

Fourth, since the printed layer is protected by the TPU by forming a printed layer on the surface of the fabric, there is no fear that the printed layer will peel off even if the mat is used for a long time.

1 is a perspective view of a conventional mat
2 is a cross-sectional view taken along line AA of FIG. 1
3 is a state diagram showing a lamination process of a conventional mat
Figure 4 is a flow chart for explaining the manufacturing method of the present invention
5A and 5B are configuration diagrams showing a manufacturing apparatus used in the present invention
Figure 6 is a longitudinal sectional view of the infant mat produced by the present invention

Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings so that those of ordinary skill in the art may easily implement the present invention. The present invention may be implemented in various different forms, and is not limited to the embodiments described herein. Note that the drawings are schematic and have not been drawn to scale. Relative dimensions and ratios of parts in the drawings are exaggerated or reduced in size for clarity and convenience in the drawings, and any dimensions are illustrative only and not limiting. In addition, the same reference numerals are used to indicate similar features to the same structure, element, or part appearing in two or more drawings.

Figure 4 is a flow chart for explaining the manufacturing method of the present invention, Figures 5a and 5b is a configuration diagram showing a manufacturing apparatus used in the present invention, Figure 6 is a longitudinal sectional view of the infant mat produced by the present invention, the present The device used in the invention is provided with a first transfer roller 120 for transferring the fabric 110 wound around the fabric loading roller 100 as shown in FIG. 5A, and the first transfer roller 120 On one side, a cooling matte roller 131 and a silicon roller 132 having a rough surface are installed, and a liquid TPU 150 is provided on top of the cooling matte roller 131 and the silicon roller 132 having a rough surface. A first TPU automatic supply unit 130 is installed to supply the upper surface of 110 so that the TPU 150 is first coated on the surface of the fabric 110.

In one embodiment of the present invention, the printed layer 111 is formed on the surface of the fabric 110 wound around the fabric loading roller 100, but if necessary, the printed layer 111 is not formed. It is understandable that (110) may be supplied by winding.

Further, a cooling matte roller 141 and a silicon roller 142 having a fine surface are installed at the rear end of the cooling matte roller 131 and the silicon roller 132 having a rough surface, and the cooling matte roller 141 having a fine surface On the top of the silicone roller 142, a second TPU automatic feeder 140 that supplies the liquid TPU 150 to the upper surface of the primary coating layer is installed, so that the TPU 150 is secondly coated on the printing layer 111. do.

However, it is understandable that only the primary coating of the TPU 150 may be applied to the surface of the printing layer 111 as needed.

The TPU 150 coated on the printed layer 111 of the fabric 110 is not hard and has a soft characteristic, even if it is cured, unlike general plastics.

Meanwhile, an embossing roller 160 that forms an embossing before solidification of the surface layer 112 coated on the upper surface of the printing layer 111 is further installed at the rear end of the cooling matte roller 141 and the silicon roller 142 with a fine surface. Alternatively, a vacuum embossing process may be further performed.

Separately, a PU (Polyurethane) sponge 210 is wound around the PU sponge winding roller 200, and a second transfer roller 220 for transporting the PU sponge 210 is installed at one side of the PU sponge winding roller 200 The third automatic TPU feeder 230 is installed on the top of the cooling roller 231 and the silicone roller 232 to supply the liquid TPU 150 to the adhesive surface of the fabric 110 and PU sponge 210 When the surface layer 112 is solidified and the surface layer 112 is supplied between the cooling roller 231 and the silicon roller 232 by the guide roller 170, the back surface of the surface layer 112 is formed That is, it is possible to apply the TPU 150 to the adhesive surface of the fabric 110 and the PU sponge 210.

The PU sponge 210 used in the present invention is lighter and cheaper than PVC, and is harmless to infants as it does not use plasticizers.

In addition, a guide roller 240 for guiding the transport of the fabric 110 and PU sponge 210 coated with the TPU 150 on the adhesive surface is installed below the cooling roller 232, and the guide roller ( At the rear end of 240), the heating compression roller 251 and the silicone roller 252 that laminate the fabric 110 and the PU sponge 210 and the laminated fabric 110 and the PU sponge 210 are provided with a conveying force. The delivery roller 260 is installed, and a first unloading roller 280 for winding the semi-finished product 270 in a roll shape is installed at the rear end of the delivery roller 260, so that the fabric 110 and PU sponge ( The semi-finished product 270 in which 210) is laminated may be wound around the semi-finished product take-up roller 280.

5B is a configuration diagram for explaining a state in which semi-finished products are fed from both sides and laminated by TPU. The semi-finished products 270 are wound around semi-finished winding rollers 280 located on both sides of the third and fourth conveying rollers 310 It is to be conveyed by the conveying force of 320, and a cooling roller 331 and a silicon roller 332 are installed between the cooling rollers 331 and the silicon roller 332, and the semi-finished product 270 is A fourth TPU automatic feeder 330 for supplying the liquid TPU 150 to the adhesive surface is installed.

A guide roller 340 for guiding the transfer of the semi-finished product 270 coated with TPU on the adhesive surface is installed under the cooling roller 331, and the semi-finished product 270 is laminated at the rear end of the guide roller 340. The heating and pressing roller 351, the silicone roller 352, and the delivery roller 360 that imparts a conveying force to the laminated mat 370 are installed, and a mat 370 is rolled at the rear end of the delivery roller 360. The mat winding roller 380 to be wound in a form is installed so that the produced mat 370 can be wound around the mat winding roller 380.

In addition to the above-described mat manufacturing apparatus, it is composed of a known cutting machine 400 for cutting the mat 370 into a predetermined size, and a known high-frequency fusing machine 500 for high-frequency fusing the edges of the mat for infants cut into a predetermined size. .

Hereinafter, the method of manufacturing the mat of the present invention by the above-described apparatus will be described in more detail.

First, the fabric 110 of a predetermined width, which was wound around the fabric loading roller 100 with the printing layer 111 formed on the surface thereof, is cooled by the first transfer roller 120 and the surface is roughly cooled matte roller 131 ) And the silicone roller 132, the first TPU automatic feeder 130 supplies the liquid TPU 150 to the printed layer 111, which is the surface of the fabric 110, so that the printed layer 111 The surface of the TPU 150 is first coated with a predetermined thickness (50 μm or less).

As described above, after the TPU 150 is first coated on the surface of the printing layer 111, the fabric 110 is continuously passed between the cooling matte roller 141 and the silicon roller 142 with a fine surface. When the second TPU automatic feeder 140 supplies the liquid TPU 150 to the upper surface of the primary coating layer, the TPU 150 is applied to the surface of the printing layer 111 at a predetermined thickness (50 µm to 100 µm). The tea is coated (S100).

First coating the TPU 150 on the upper surface of the printed layer 111 of the fabric 110 using a cooling matte roller 131 having a rough surface, and then using a cooling matte roller 141 having a fine surface. The reason for coating is to increase the adhesion while increasing the matte effect of the surface layer 112.

The thicker the thickness of the TPU 150 coated on the surface of the printing layer 111 is, the more advantageous it is in terms of touch as well as durability, but the workability decreases due to time delay due to the solidification of the TPU 150 as well as an increase in cost. Therefore, it is preferable to set it to 50 μm to 100 μm.

As described above, the TPU 150 coated twice on the surface of the printing layer 111 is solidified during transport to form a soft surface layer 112 on the upper surface of the printing layer 111, so when using the mat 370 In addition to improving the tactile feel, it is expected to prevent the occurrence of noise when walking the mat, and to prevent the phenomenon that the print layer 111 is damaged.

As described above, it is preferable to use the TPU 150 coated on the surface of the printing layer 111 with a low viscosity (strength). The surface of the mat 370 is soft and the strength is strengthened to improve the touch. It is to do.

However, if necessary, the surface layer 112 may be formed by applying only the first coating of the TPU 150 to the upper surface of the printed layer 111 printed on the fabric 110 to a predetermined thickness (50 μm to 100 μm). Yes is understandable.

After forming the surface layer 112 by coating the TPU 150 on the upper surface of the printing layer 111 in the same manner as described above, the fabric 110 is guided by the guide roller 170 to form the cooling roller 231 and the silicone. When transferred between the rollers 232, the PU sponge 210 that was wound on the PU sponge winding roller 200 is transferred together between the cooling roller 231 and the silicone roller 232 by the second transfer roller 220 Meanwhile, the TPU layer 151 is formed by supplying the liquid TPU 150 to the adhesive surface thereof by the third automatic TPU supply unit 230.

Thereafter, after the TPU 150 is coated on the adhesive surface of the fabric 110 and the PU sponge 210, they are guided by the guide roller 240 and the heating compression roller 251 and the silicone roller 252 The semi-finished product 270 can be obtained because it is compressed and laminated while passing through the semi-finished product winding roller 280 by the conveying force of the delivery roller 260 (S200).

The semi-finished products 270 produced in this way and wound on the semi-finished winding roller 280 are cooled by the transfer force of the third and fourth transfer rollers 310 and 320 from both sides as shown in FIG. 5B. When the liquid TPU 150 is supplied to the adhesive surface of the semi-finished product 270 from the fourth TPU automatic feeder 330 while supplying between), the TPU layer 152 is formed on the adhesive surface thereof.

The viscosity (strength) of the TPU 150 forming the TPU layers 151 and 152 is preferably higher than the TPU 150 forming the surface layer 112, which is bonded to each other. ) And the PU sponge 210, and to increase the adhesion between the PU sponge and the PU sponge.

After that, the semi-finished product 270 is guided by the guide roller 340 in a state where the TPU 150 is coated on the adhesive surface, and is compressed and laminated while passing between the heating pressing roller 351 and the silicone roller 352. Since it is wound around the mat winding roller 380 by the feed force of the next delivery roller 360, the mat 370 can be obtained (S300).

After producing the mat 370 by the method as described above, the mat 370 is cut to a predetermined size using a known cutter 400, and then the frame is high-frequency fused using a high-frequency splicer 500. The mat is completed (S400 to S500).

Although the embodiments of the present invention have been described above with reference to the accompanying drawings, those of ordinary skill in the art to which the present invention pertains can understand that it can be implemented in other specific forms without changing the technical idea or essential features. will be.

Therefore, it should be understood that the embodiments described above are illustrative in all respects and not limiting, and the scope of the present invention described in the detailed description is indicated by the claims to be described later, and the meaning of the claims and The scope and all changes or modifications derived from the concept of equivalent should be construed as being included in the scope of the present invention.

110: fabric 111: printed layer
112: surface layer 131: matte roller with a rough surface
132, 232: silicone roller 150: TPU
151, 152: TPU layer 160: embossing roller
210: PU sponge 251, 351: heating pressing roller
252, 352: silicone roller 270: semi-finished product
370: Matt

Claims (5)

A printed layer 111 is formed on the surface and a liquid TPU 150 is supplied to the upper surface of the printed layer 111 while supplying a fabric 110 having a predetermined width to solidify the TPU to a thickness of 50 μm to 100 μm. The step of forming the surface layer 112 of the surface layer 112, while transporting the fabric 110 and the PU sponge 210 on which the surface layer 112 is formed, respectively, supplying a liquid TPU having a higher viscosity than the surface layer to the adhesive surface of the TPU layer After forming 151, the step of obtaining a semi-finished product 270 by applying heat while passing through the heating pressing roller 251 and the silicon roller 252 to laminate, and supplying the semi-finished product 270 from both sides of a PU sponge ( After applying the liquid TPU 150 to the adhesive surface of 210), applying heat while passing through the heating pressing roller 351 and the silicone roller 352 to laminate them, and the laminated mat 370 to a predetermined size. A method for manufacturing a mat for child-rearing using a fabric as an intermediate core material, characterized in that comprising the step of cutting with and finishing the edge of the mat cut to a predetermined size. The method according to claim 1,
A method for manufacturing a mat for child care using a fabric as an intermediate core material, characterized in that the liquid TPU 150 is first and secondly coated on the upper surface of the printing layer 111 while supplying the fabric 110 to solidify. The method according to claim 2,
The first coating of the liquid TPU 150 is carried out while passing the cooling matte roller 131 and the silicon roller 132 having a rough surface, and the secondary coating is a cooling matte roller 141 and the silicon roller 142 having a fine surface. A method of manufacturing a mat for child-rearing using a fabric as an intermediate core material, characterized in that while passing through). delete The method according to claim 1,
Before the TPU of the surface layer 112 is solidified, it passes through the embossing roller 160 so that embossing is formed on the surface layer 112. A method of manufacturing a mat for child-rearing using a fabric as an intermediate core material.

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