A processing mold and a processing method of a breakage-proof foldable pad

Abstract

This invention provides a processing mold and processing method for a break-resistant foldable pad, comprising three integrally molded pad bodies connected sequentially by flaps, with a spacing of 15-25mm between two adjacent pad bodies; the pad bodies, from the outside to the inside, sequentially include a first self-skinning layer and a PU foam layer, and the bottom edges of two adjacent pad bodies are chamfered with C=10-15mm and α=30° to form a folded chamfer; the flaps are located on the edge of the folded chamfer near the upper surface of the pad body, and the flaps, from the outside to the inside, sequentially include a second self-skinning layer and a reinforcing sheet, the reinforcing sheet including a base plate with the same length as the pad body and a width not less than the spacing between two adjacent pad bodies, the base plate being "I"-shaped, with several positioning holes spaced apart on the base plate, the reinforcing sheet being made of a high-flexibility polymer composite material, and the thickness of the flaps being 3-5mm.

Description

Technical Field

[0001] This invention relates to the field of self-skinning PU foam pad technology, and more particularly to a break-resistant foldable pad, its processing mold, and processing method. Background Technology

[0002] A seat cushion is a mat placed on the surface of a seat to keep the seat clean while also providing warmth and comfort; a standing mat is a mat used in daily life to elevate the feet and improve foot comfort.

[0003] With the widespread application of PU materials in the cushion industry, self-skinning cushions are gradually becoming more common in daily life. Compared to cushions made of traditional knitted, cotton, or nylon materials, self-skinning PU foam cushions are more resistant to dirt and wear, and have a longer lifespan. However, PU material itself has good elasticity and recovery capabilities, making these cushions difficult to fold and store; they are difficult to roll up and easily unravel. Furthermore, PU has poor folding properties; traditional self-skinning cushions are prone to creases after folding, and repeated folding can lead to breakage and pilling along the creases, ultimately resulting in damage or reduced softness. Self-skinning PU foam standing cushions do not have folding capabilities, requiring multiple cushions to be stacked when used for elevation. This can easily lead to slippage between the cushions, reducing comfort and posing certain safety hazards.

[0004] In addition, traditional standing mats usually take up more space than sitting mats. If they only serve their own functions, their functionality is relatively limited. There is a need for a mat that can be used as both a sitting mat and a standing mat to expand its application and make it more convenient and comfortable for users. Summary of the Invention

[0005] To solve the above problems, the present invention provides a processing mold for a break-resistant foldable pad, which is implemented as follows: A foldable mat that is resistant to breakage includes several integrally molded mat bodies connected in sequence by flaps, with a spacing of 15~25mm between two adjacent mat bodies. The pad body includes a first self-skinning layer and a PU foam layer from the outside to the inside. The bottom edge of the two adjacent pad bodies is chamfered with C=10~15mm and α=30° to form a chamfer. The flap is located on the edge of the chamfered corner near the upper surface of the pad. The flap includes a second self-skinning layer and a reinforcing sheet from the outside to the inside. The reinforcing sheet includes a base plate with the same length as the pad and a width not less than the distance between two adjacent pads. The base plate is in the shape of an "I". Several positioning holes are spaced apart on the base plate. The reinforcing sheet is made of a high-flexibility polymer composite material. The thickness of the flap is 0.5~5mm.

[0006] As a further improvement, the pad specifically includes a main pad body and secondary pad bodies symmetrically arranged on both sides of the main pad body, wherein the bottom width of the secondary pad body is 1 / 2 of the bottom width of the main pad body.

[0007] As a further improvement, a plurality of first soft magnetic sheets are embedded in the bottom surface of the main pad body, and a plurality of second soft magnetic sheets are embedded in the bottom surface of the secondary pad body. After the secondary pad body is folded and flipped toward the main pad body, and the bottom surface of the main pad body and the bottom surface of the secondary pad body are attached together, the positions of the first soft magnetic sheets and the second soft magnetic sheets correspond to each other.

[0008] As a further improvement, the reinforcing sheet is made of PVC and a base fabric composite.

[0009] The present invention provides a processing mold for a break-resistant foldable pad, used to produce a break-resistant foldable pad as described above, comprising a detachably configured upper mold core and a lower mold core; The lower mold core includes a base body, the upper surface of which is recessed to form a molding cavity. The molding cavity is divided into a main chamber and auxiliary chambers symmetrically arranged on both sides of the main chamber by a partition plate. The upper surface of the partition plate is provided with a plurality of positioning pins that are adapted to the positioning holes. Two feed ports are opened on any long side of the molding cavity along the arrangement direction of the main chamber and the auxiliary chambers. The feed ports are located at positions corresponding to the partition plate. The upper mold core includes a cover plate, and a forming platform adapted to the main cavity is provided on the lower surface of the cover plate. Ribs corresponding to the partition plate are protruding on the forming platform. The upper mold core and the lower mold core are detachably connected by a locking component.

[0010] As a further improvement, each of the feed inlets is provided with a high-pressure gun head, and a diversion nozzle is connected to the side of the high-pressure gun head near the forming cavity. An even number of discharge ports are opened on the side of the diversion nozzle away from the high-pressure gun head. The even number of discharge ports are evenly divided by the partition plate and are respectively connected to the main chamber and the secondary chamber.

[0011] As a further improvement, each of the feed inlets is equipped with a high-pressure nozzle. A diversion nozzle is connected to the side of the high-pressure nozzle closest to the forming cavity. An odd number of discharge ports are opened on the side of the diversion nozzle away from the high-pressure nozzle. The odd number of discharge ports are separated by the partition plate and are respectively connected to the main chamber and the secondary chamber. In each group of high-pressure nozzles, the number of diversion nozzles connected to the main chamber is one more than the number of diversion nozzles connected to the secondary chamber.

[0012] As a further improvement, the two feed inlets are connected by a pipe connecting groove opened on the upper surface of the substrate. The high-pressure gun head includes a main pipe, which extends to both sides after entering the connecting groove to form two secondary pipes. The secondary pipes are connected to the diverter nozzle pipe.

[0013] The present invention further provides a method for processing a break-resistant foldable pad, for producing a break-resistant foldable pad as described above, comprising the following steps: S1. Preparation of reinforcing sheet; S2. The reinforcing sheet is placed into the mold for positioning, and PU material and foaming agent are injected into the mold for foaming; S3. Remove the product for shaping and trimming, and cut a groove on the bottom surface of the pad and embed a soft magnetic sheet; S4. Complete the processing.

[0014] Specifically, the mold is a processing mold for a break-resistant foldable pad as described above.

[0015] The beneficial effects of this invention are as follows: 1. By integrally molding several pads connected in sequence by flaps, the pads can be folded at the flap connection points, avoiding creases and damage caused by folding.

[0016] 2. Since the flap is integrally foamed with the padding, if it is simply connected by the self-foaming, self-skinning structure of PU, it is still prone to breakage after repeated folding. Therefore, by setting a reinforcing sheet made of PVC and base fabric composite inside the flap, the reinforcing sheet bears the wear and tear from folding, resulting in a higher lifespan after a longer number of folds compared to the PU foam-molded parts.

[0017] In addition, the reinforcing sheet, which is a composite of PVC and the base fabric, has inherent elasticity, which ensures that when the pad is folded, the flaps do not stick together but instead form a short arc shape. This prevents the second self-skinning layer at the flap position from tearing, cracking, or pilling due to a complete 180° fit. Furthermore, even if the second self-skinning layer is damaged, the reinforcing sheet can continue to connect the layers, preventing separation between the pads.

[0018] 3. A chamfer of C=10~15mm and α=30° is made on the bottom edge of the adjacent side of the cushion to form a folded chamfer. The flap is located on the edge of the chamfer near the upper surface of the cushion. This ensures that when the cushion is folded open, there is a 20~30mm gap between the two parts of the flap that meet the cushion. This prevents the flap from completely fitting together at the end away from the cushion, thus avoiding damage such as tearing, cracking, or pilling. Furthermore, when the cushion is unfolded, direct contact between the flap and the seat, bench, or floor prevents friction damage and further extends the lifespan of the flap.

[0019] 4. By setting the substrate to an "I" shape, the following advantages are achieved: ①. Increasing the surface area of ​​the connection point between the reinforcing sheet and the pad exposed to the outside also increases the contact area between the reinforcing sheet and the pad close to the outside, improving the connection strength and stability, and preventing tearing and separation between the reinforcing sheet and the pad starting from the outer end.

[0020] ②. If the reinforcing strip is too wide, the portion embedded within the padding after folding will exert significant force on weak points in the padding due to its elastic recovery, potentially causing damage. Conversely, if the reinforcing strip is too narrow, it may separate from the padding, leading to tearing of the flap. The "I"-shaped design ensures the stability and strength of the connection between the reinforcing strip and the padding, while preventing the reinforcing strip from affecting weak points in the padding when folded.

[0021] 5. By creating positioning holes on the substrate, the substrate will not flow or slip during the injection of PU and foaming agent during the remolding process, ensuring a fixed position and improving the quality of the processed product.

[0022] 6. The one-piece molding process avoids stress concentration at connection seams and connection points caused by later connection processing between pads, which would increase the possibility of breakage during actual use.

[0023] 7. When unfolded, it can be used as a standing mat. Because it is made of PU foam, it has a comfortable feel when stepped on, providing users with a high level of comfort. When folded, it is stable and can be used as a raised standing mat or as a seat cushion. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of the overall structure of the present invention.

[0025] Figure 2 This is a front view structural diagram of the present invention.

[0026] Figure 3 This is a schematic diagram of the flipping and folding direction of the present invention.

[0027] Figure 4 This is a partially enlarged cross-sectional view of the connection between the main pad and the secondary pad of the present invention.

[0028] Figure 5 This is an exploded structural diagram of the mold of the present invention.

[0029] Figure 6 This is a schematic diagram of the overall structure of the lower mold core of the mold of the present invention.

[0030] Figure 7 This is a schematic diagram of the overall structure of the high-pressure gun head of the present invention. Detailed Implementation

[0031] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of the present invention, not all of them. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention. Therefore, the following detailed description of the embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention.

[0032] In the description of this invention, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, a feature defined with "first" and "second" may explicitly or implicitly include one or more of that feature.

[0033] A foldable mat that is resistant to breakage includes several integrally molded mat bodies 1 connected in sequence by flaps 2, with a spacing of 15~25mm between two adjacent mat bodies 1. The pad 1 includes a first self-skinning layer 15 and a PU foam layer 16 from the outside to the inside. The bottom edge of the two adjacent pads 1 is chamfered with C=10~15mm and α=30° to form a chamfer. The flap 2 is located on the edge of the chamfered corner near the upper surface of the pad 1. The flap 2 includes a second self-skinning layer 21 and a reinforcing sheet 22 from the outside to the inside. The reinforcing sheet 22 includes a base plate with the same length as the pad 1 and a width not less than the distance between two adjacent pads 1. The base plate is in the shape of an "I". Several positioning holes are spaced apart on the base plate. The reinforcing sheet 22 is made of a high-flexibility polymer composite material. The thickness of the flap 2 is 0.5~5mm.

[0034] Specifically, the cushion body 1 consists of three parts. As a further improvement, each cushion body 1 includes a main cushion body 11 and two secondary cushion bodies 12 symmetrically arranged on both sides of the main cushion body 11. The bottom edge width of each secondary cushion body 12 is half the bottom edge width of the main cushion body 11. That is, when the two secondary cushion bodies 12 are folded towards the main cushion body 11, their opposite sides will meet when unfolded. For underage users or when used in a car, the folded area is smaller, while the vertical height increases, making it more convenient for young children to sit on.

[0035] As a further improvement, the reinforcing sheet 22 is made of PVC and a base fabric composite.

[0036] Since the reinforcing sheet 22 is made of PVC composite base fabric, it has strong elastic recovery ability. After the pad body 1 is folded, it is easier to be pulled apart by the reinforcing sheet 22. In order to ensure the stability of the folded shape, as a further improvement, a number of first soft magnetic sheets 14 are embedded in the bottom surface of the main pad body 11, and a number of second soft magnetic sheets 13 are embedded in the bottom surface of the secondary pad body 12. When the secondary pad body 12 is folded and flipped towards the main pad body 11, and the bottom surface of the main pad body 11 is attached to the bottom surface of the secondary pad body 12, the positions of the first soft magnetic sheets 14 and the second soft magnetic sheets 13 correspond.

[0037] Since the product provided by this invention is integrally molded, including multiple pads 1 and reinforcing pieces 22 embedded in the connecting flaps 2 between the pads 1, traditional processing methods are difficult to implement. Therefore, this invention also provides a processing mold 3 for a break-resistant foldable pad, used to produce a break-resistant foldable pad as described above, including a detachable upper mold core 32 and a lower mold core 31; The lower mold core 31 includes a base 311, the upper surface of which is recessed to form a molding cavity 312. The molding cavity 312 is divided by a partition plate 313 into a main cavity 3121 and a secondary cavity 3122 symmetrically arranged on both sides of the main cavity 3121. The upper surface of the partition plate 313 is provided with a plurality of positioning pins 3131 that are adapted to the positioning holes. The molding cavity 312 has two feed ports 314 on any long side along the arrangement direction of the main cavity 3121 and the secondary cavity 3122. The feed ports 314 are located at positions corresponding to the partition plate 313. The upper mold core 32 includes a cover plate, and the lower end surface of the cover plate is provided with a forming platform adapted to the main cavity 3121. The forming platform is provided with ribs corresponding to the partition plate 313. The upper mold core 32 and the lower mold core 31 are detachably connected by a locking member 33.

[0038] This mold 3 achieves the following benefits: 1. The main molding cavity 312 of the molding pad 1 is formed in the lower mold core 31. The molding cavity 312 is divided by the partition plate 313. At the same time, the partition plate 313 is also provided with the positioning pin 3131. This realizes that the partition plate 313 divides the molding cavity 312 while the positioning pin 3131 fixes the reinforcing piece 22, preventing the reinforcing piece 22 from being displaced, shifted, or twisted due to the injection of PU material and foaming agent, thus ensuring the molding quality of the product.

[0039] 2. Ensure that the reinforcing piece 22 can be embedded inside the pad 1 and the flap 2 without post-processing. The folding of the flap 2 is achieved by the reinforcing piece 22, making the molding simpler and the product with a longer service life.

[0040] Since the molded pad 1 is made of PU foam, during injection, in order to ensure that the foam can fill the cavity after foaming, that is, the material can enter the far end of the molding cavity 312, a further improvement is made. Each of the inlets 314 is provided with a high-pressure nozzle 4. The side of the high-pressure nozzle 4 closest to the molding cavity 312 is connected to a diversion nozzle 41. The diversion nozzle 41 has an even number of outlets on the side away from the high-pressure nozzle 4. The even number of outlets are evenly divided by the partition plate 313 and are respectively connected to the main chamber 3121 and the secondary chamber 3122.

[0041] As a further improvement, each of the feed inlets 314 is provided with a high-pressure nozzle 4. The side of the high-pressure nozzle 4 closest to the forming cavity 312 is connected to a diversion nozzle 41. The diversion nozzle 41 has an odd number of discharge ports on the side away from the high-pressure nozzle 4. The odd number of discharge ports are separated by the partition plate 313 and are respectively connected to the main cavity 3121 and the secondary cavity 3122. The number of diversion nozzles 41 connected to the main cavity 3121 on each group of high-pressure nozzles 4 is one more than the number of diversion nozzles 41 connected to the secondary cavity 3122.

[0042] As a further improvement, the two feed ports 314 are connected by a pipe connecting groove 315 opened on the upper end surface of the base 311. The high-pressure nozzle 4 includes a main pipe. After entering the connecting groove 315, the main pipe extends to both sides to form two secondary pipes. The secondary pipes are connected to the pipes of the diverting nozzle 41.

[0043] The present invention further provides a method for processing a break-resistant foldable pad, for producing a break-resistant foldable pad as described above, comprising the following steps: S1. Prepare reinforcing sheet 22; S2. The reinforcing sheet 22 is placed into the mold 3 for positioning, and PU material and foaming agent are injected into the mold 3 for foaming; S3. Take out the product for shaping and trimming, and cut a groove on the bottom surface of the pad 1 and embed a soft magnetic sheet; S4. Complete the processing.

[0044] Specifically, the mold 3 is a processing mold 3 for a break-resistant foldable pad as described above.

[0045] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the invention by those skilled in the art. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of the invention should be included within the scope of protection of the invention.

Claims

1. A processing mold for a break-resistant foldable pad, characterized in that, This invention relates to the production of a breakable foldable mat, the foldable mat comprising several integrally molded mat bodies connected sequentially by flaps, each mat body comprising, from the outside in, a first self-skinning layer and a PU foam layer, each flap comprising, from the outside in, a second self-skinning layer and a reinforcing sheet, each reinforcing sheet comprising a base plate having the same length as the mat body and a width not less than the distance between two adjacent mat bodies, the base plate being in the shape of an "I" and having several positioning holes spaced apart on the base plate, and the processing mold comprising a detachably disposed upper mold core and a lower mold core; The lower mold core includes a base body, the upper surface of which is recessed to form a molding cavity. The molding cavity is divided into a main chamber and auxiliary chambers symmetrically arranged on both sides of the main chamber by a partition plate. The upper surface of the partition plate is provided with a plurality of positioning pins that are adapted to the positioning holes. Two feed ports are opened on any long side of the molding cavity along the arrangement direction of the main chamber and the auxiliary chambers. The feed ports are located at positions corresponding to the partition plate. The upper mold core includes a cover plate, and a forming platform adapted to the main cavity is provided on the lower surface of the cover plate. Ribs corresponding to the partition plate are protruding on the forming platform. The upper mold core and the lower mold core are detachably connected by a locking component.

2. The processing mold for a break-resistant foldable pad as described in claim 1, characterized in that, Each of the feed inlets is equipped with a high-pressure gun head. A diversion nozzle is connected to the side of the high-pressure gun head near the forming cavity. An even number of discharge ports are opened on the side of the diversion nozzle away from the high-pressure gun head. The even number of discharge ports are evenly divided by the partition plate and are respectively connected to the main chamber and the secondary chamber.

3. The processing mold for a break-resistant foldable pad as described in claim 2, characterized in that, Each of the feed inlets is equipped with a high-pressure nozzle. A diversion nozzle is connected to the side of the high-pressure nozzle closest to the forming cavity. An odd number of discharge ports are opened on the side of the diversion nozzle away from the high-pressure nozzle. The odd number of discharge ports are separated by the partition plate and are respectively connected to the main chamber and the secondary chamber. The number of diversion nozzles connected to the main chamber on each set of high-pressure nozzles is one more than the number of diversion nozzles connected to the secondary chamber.

4. The processing mold for a break-resistant foldable pad as described in claim 2 or 3, characterized in that, The two feed inlets are connected by a pipe connecting groove opened on the upper surface of the substrate. The high-pressure gun head includes a main pipe. After entering the connecting groove, the main pipe extends to both sides to form two secondary pipes. The secondary pipes are connected to the diversion nozzle pipe.

5. A method for processing a break-resistant foldable pad, characterized in that, The processing method is based on the processing mold as described in claim 1, and includes the following steps: S1. Preparation of reinforcing sheet; S2. The reinforcing sheet is placed into the mold for positioning, and PU material and foaming agent are injected into the mold for foaming; S3. Remove the product for shaping and trimming, and cut a groove on the bottom surface of the pad and embed a soft magnetic sheet; S4. Complete the processing.

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