A method for manufacturing a wire-drawn air mattress

Abstract

A method for manufacturing a wire-drawn inflatable mattress, relating to the field of mattress technology, primarily addresses how to simplify the structure and improve yield. The method involves first fixing and trimming the cut top and bottom layers to reinforcing strips. Then, the top and bottom layers are welded to both sides of the wire-drawn body and trimmed. Next, the two ends of a retaining band equipped with air nozzles and an electric pump are clamped between the top and bottom layers and the reinforcing strips, respectively, and welded sequentially from bottom to top. Finally, excess edges are trimmed and airtightness is checked to ensure stability during use. The retaining band covers the sides of the mattress, connecting the top and bottom layers. During inflation, the retaining band gradually approaches the sides of the wire-drawn body, ensuring that the entire surface of the mattress has support after inflation. This method simplifies the structure and, by installing the reinforcing strips before welding the wire-drawn body, facilitates positioning during use, thereby improving the yield rate.

Description

Technical Field

[0001] This invention belongs to the field of mattress technology, and specifically relates to a method for manufacturing a wire-drawn air mattress. Background Technology

[0002] Inflatable mattresses, as stable, lightweight, and easy-to-store mattresses, are widely used in outdoor camping and other situations where storage requirements are high. Commonly used inflatable mattresses on the market form air chambers by bonding the top and bottom layers with surrounding materials, and connecting the top and bottom layers with straps. This ensures sufficient support when inflated. However, because the sides are connected by straps, the top and bottom layers, and the surrounding materials, the mattress lacks effective support around its edges after inflation. When the user's center of gravity is close to the side of the mattress, the poor support can cause them to fall, resulting in low comfort and a negative impact on the user experience. Summary of the Invention

[0003] The purpose of this invention is to address the aforementioned problems in existing technologies by proposing a method for manufacturing a wire-drawn air mattress. The technical problem to be solved by this invention is: how to simplify the structure and improve the yield rate.

[0004] The present invention can be achieved through the following technical solution: a method for manufacturing a wire-drawn air mattress, comprising a wire-drawn body, a surface layer, a bottom layer, and a surrounding band formed by cutting, wherein the surrounding band is equipped with an electric pump and an air nozzle, the surrounding band (4) is first fused to the inner side of the reinforcing band (4a) on the surface layer (2), then fused to the outer side of the surface layer (2), then fused to the outer side of the bottom layer (3), and finally fused to the inner side of the reinforcing band (4a) on the bottom layer (3), and the surrounding band (4) is welded to the mattress body from top to bottom using a high-frequency welding device along the height direction of the wire-drawn air mattress, and includes the following steps:

[0005] S1. Weld the outer edges of both the top and bottom layers to the reinforcing strips, trim and control the corresponding dimensions of the reinforcing strips, and then place them on the workbench to prepare for the next step.

[0006] S2. Remove the welded top and bottom layers from the workbench and weld them to the wire drawing body to form the mattress body. Then place it on the workbench, cut and control the size of the top and bottom layers, and prepare for the next step.

[0007] S3. Remove the mattress body from the workbench and weld one side of the cut surface layer to the outer side of the upper end of the wrapping strip through the reinforcing strip, and weld the other side directly to the inner side of the upper end of the wrapping strip.

[0008] S4. Weld the outer side of the lower end of the webbing to the reinforcing strip at the bottom layer, and weld the inner side of the lower end of the webbing directly to the bottom layer. After welding, place the finished product on the workbench.

[0009] S5. After welding the finished upper band to the mattress body, trim off the excess edges and then package it.

[0010] The technical solution of this application mainly involves a mattress body formed by welding the top layer and bottom layer to the brushed body. The inner side of the surrounding band is directly connected to the outer side of the top and bottom layers, and the outer side of the surrounding band is welded to the top and bottom layers via reinforcing bands. This allows the surrounding band to stretch towards both ends after the mattress is inflated due to the volume change of the mattress body, gradually straightening the band and maintaining the flatness of the mattress sides. This also ensures the band is as close as possible to the brushed body, improving aesthetics while ensuring that, under localized stress, the supporting area is the same as the mattress area after inflation, thus maximizing the stress distribution across the entire mattress. To maintain consistency, and because the side panel in the middle is removed after storage, the structure of the mattress is simplified, making it easier to roll up and store. The reinforcing strip is welded to the surrounding strip first, and then the top and bottom layers are welded to the surrounding strip, which facilitates processing and further improves the production efficiency of the air mattress. After each welding is completed, it needs to be trimmed and adjusted on the workbench before proceeding to the next processing step. This avoids excessively long edges from affecting processing and further improves the yield rate of the air mattress by pre-treating it for the next processing step, preventing wrinkles during transfer.

[0011] In the above-mentioned method for manufacturing a wire-drawing air mattress, after step S1 is completed and the mattress body is placed on the workbench, it is checked for any leakage or folding, and then placed in the unqualified area.

[0012] In the aforementioned manufacturing method of the wire-stretched air mattress, the reinforcing strip is welded to the surface layer or the bottom layer using a high-frequency welding device, and an external indentation is formed on the reinforcing strip. By welding the reinforcing strip to the surface layer and the bottom layer using high-frequency pressing and forming an external indentation after welding, the presence of breaks can be checked during inspection, thus more intuitively determining whether there are defects such as pressure leakage or incomplete welding, thereby improving the yield rate of the production.

[0013] In the above-mentioned method for manufacturing a wire-drawn air mattress, in step S2, after the surface layer and the bottom layer are laid flat, the wire-drawn body is welded to the surface layer and the bottom layer using a high-frequency welding device, and an inner indentation is formed on both the surface layer and the bottom layer.

[0014] In the above-described method for manufacturing a wire-drawn air mattress, before step S3, lines are drawn on the surrounding band, and the air nozzle is fixed to the surrounding band. Then, an electric pump hole is made on the surrounding band, and the electric pump is pressed in through a mold. The steps of drawing lines on the surrounding band, fixing the air nozzle, and pressing in the electric pump are performed simultaneously with steps S1 and S2.

[0015] In the above-described manufacturing method for a wire-drawn air mattress, after the surrounding band is cut, the locations where holes need to be made are marked and lines are drawn. Air nozzles are then passed through the surrounding band and welded. After cooling, the surrounding band with the air nozzles is placed on a workbench, with the side of the air nozzle with the pull ring facing outwards. During processing, the relative position of the pull rings facilitates determining the direction of the surrounding band, improving processing efficiency and reducing the defect rate caused by incorrect band orientation in later processing stages.

[0016] In the above-mentioned method for manufacturing a wire-drawing air mattress, the shroud on the workbench is removed, and an electric pump hole is made in the shroud. Then, the electric pump is fixed to the shroud through the electric pump hole using a mold.

[0017] In the above-mentioned method for manufacturing a wire-drawn air mattress, in step S6, before cutting off the excess edge, an inspection is conducted on the workbench to check for any appearance defects, and a sample is taken for testing after the excess edge is cut off.

[0018] Compared with the prior art, the present invention has the following advantages:

[0019] 1. This solution directly welds the surface layer and reinforcing strip to the surrounding strip, allowing the surrounding strip to gradually stretch during the inflation of the air mattress, making it fit as closely as possible to the side of the fabric body, increasing the support surface and ensuring even force distribution on the mattress. The two ends of the surrounding strip are welded to the fabric body from top to bottom, and then trimmed after welding to avoid excessive fabric length affecting usability and aesthetics. The surrounding strip is directly connected to the surface layer, and the reinforcing strip enhances the connection strength, simplifying the structure. The finished surface and bottom layers are transferred via a workbench, and the surrounding strip is welded to the mattress body from top to bottom. This improves processing efficiency, and the workbench allows for adjustment and trimming, thereby increasing the yield rate of the air mattress.

[0020] 2. In this solution, the top layer and bottom layer are welded to the reinforcing strip and the wire drawing body, respectively, and an inner indentation and an outer indentation are formed at the connection. While ensuring the connection strength, the presence of breakpoints and their relative positions on the indentation can be used to determine whether there is any leakage or mis-welding, thereby improving the product yield. Attached Figure Description

[0021] Figure 1 This is a three-dimensional sectional view of the present invention;

[0022] Figure 2 This is a flowchart illustrating the present invention.

[0023] In the figure: 1. Brushed body; 2. Top layer; 3. Bottom layer; 4. Enclosure; 4a. Reinforcing strip; 4b. Electric pump hole; 5. Electric pump; 6. Air nozzle; 6a. Pull ring; 7. Outer indentation; 8. Inner indentation. Detailed Implementation

[0024] The following are specific embodiments of the present invention, which are described in conjunction with the accompanying drawings. However, the present invention is not limited to these embodiments.

[0025] like Figure 1 As shown, this brushed mattress includes a top layer 2, a bottom layer 3, and a brushed body 1 that connects the support surfaces of the top layer 2 and the bottom layer 3. The top layer 2 and the bottom layer 3 are also connected by a band 4 located on the side of the brushed body 1. Each end of the band 4 has a reinforcing band 4a. One end of the reinforcing band 4a is fused to the top layer 2 and the bottom layer 3 using a high-frequency welding device to form an outer indentation 7. The other end is fused to the outer sides of both ends of the band 4. The inner sides of the ends of the band 4 are fused to the outer sides of the top layer 2 and the bottom layer 3, respectively. An air nozzle 6 and an electric pump 5 are installed in the middle of the band 4. The top layer 2, the bottom layer 3, and the brushed body 1 are fused to form an inner indentation 8.

[0026] like Figure 2 As shown, after pre-processing such as marking and cutting the brushed body 1, surface layer 2, bottom layer 3, and reinforcing strip 4a, the main processing steps of this brushed mattress are as follows:

[0027] S1. Weld the outer edges of the surface layer 2 and the bottom layer 3 to the reinforcing strip 4a, trim and control the corresponding dimensions of the reinforcing strip 4a, then place it on the workbench and check for any leakage or folding. Place the defective products in the defective product area, and then further process the qualified products.

[0028] S2. Remove the welded top layer 2 and bottom layer 3 from the workbench, and lay the top layer 2 and bottom layer 3 flat. Then, weld the top layer 2 and bottom layer 3 to the wire drawing body 1 using a high-frequency welding device to form an inner indentation 8 on both the top layer 2 and bottom layer 3, forming the mattress body. Then, place it on the workbench, and cut and control the size of the top layer 2 and bottom layer 3 before preparing for the next step.

[0029] S3. Remove the mattress body from the workbench and weld one side of the cut surface layer 2 to the outer side of the upper end of the wrapping strip 4 via the reinforcing strip 4a, and weld the other side directly to the inner side of the upper end of the wrapping strip 4.

[0030] S4. Weld the outer side of the lower end of the sheath 4 to the reinforcing strip 4a located in the bottom layer 3, and weld the inner side of the lower end of the sheath 4 directly to the bottom layer 3. After welding, place the finished product on the workbench.

[0031] S5. Place the finished product on the workbench and check for any appearance defects. Products with appearance defects should be placed in the non-conforming product area. After the qualified products are flattened, the excess edges should be removed and samples sent for testing. After the testing is completed, the products should be packaged.

[0032] Before welding the outer band 4 to the mattress body, lines are drawn on the pre-cut outer band 4, and holes for installing the air nozzle 6 and the electric pump 5 are made according to the drawn lines. The dimensions of the overlapping parts when welding the reinforcing band 4a to the top layer 2 and the bottom layer 3 are also determined, facilitating the subsequent welding of the top layer 2, the bottom layer 3, and the reinforcing band 4a. After drilling the holes, the air nozzle 6 is pressed into the outer band 4 using equipment, with the side of the air nozzle 6 with the pull ring 6a facing outwards. It is then placed on a workbench, arranged one by one with the pull ring 6a facing outwards. Finally, the electric pump 5 is pressed into the electric pump 5 hole 4b on the outer band 4 using a mold.

[0033] In this brushed mattress, the mattress body and the surrounding band 4 are welded together from top to bottom along the height direction of the mattress using a high-frequency welding device. This process involves first welding the band to the inner side of the reinforcing band 4a on the surface layer 2, then to the outer side of the surface layer 2, then to the outer side of the bottom layer 3, and finally to the inner side of the reinforcing band 4a on the bottom layer 3. This facilitates processing and improves production efficiency. Furthermore, welding the reinforcing band 4a first, followed by welding it to the brushed body 1, allows for better positioning of the surface layer 2 and bottom layer 3 during the fixation process, reducing the risk of defective products due to misalignment. This ensures sufficient support for the brushed mattress while improving production efficiency.

[0034] The specific embodiments described herein are merely illustrative of the spirit of the invention. Those skilled in the art to which this invention pertains may make various modifications or additions to the described specific embodiments or use similar methods to substitute them, without departing from the spirit of the invention or exceeding the scope defined by the appended claims.

[0035] Although this document frequently uses terms such as 1. wire drawing body; 2. surface layer; 3. bottom layer; 4. sheathing; 4a. reinforcing strip; 4b. electric pump hole; 5. electric pump; 6. air nozzle; 6a. pull ring; 7. external indentation; 8. internal indentation, the possibility of using other terms is not excluded. The use of these terms is merely for the convenience of describing and explaining the essence of the invention; interpreting them as any additional limitation would contradict the spirit of the invention.

Claims

1. A method for manufacturing a wire-drawn air mattress, comprising a wire-drawn body (1), a surface layer (2), a bottom layer (3), and a surrounding band (4) formed by cutting, wherein the surrounding band (4) is provided with an electric pump (5) and an air nozzle (6), characterized in that, The surrounding band (4) is first fused to the inner side of the reinforcing band (4a) on the surface layer (2), then fused to the outer side of the surface layer (2), then fused to the outer side of the bottom layer (3), and finally fused to the inner side of the reinforcing band (4a) on the bottom layer (3). Along the height direction of the drawn air mattress, the surrounding band (4) is welded to the mattress body from top to bottom using a high-frequency welding device, and includes the following steps: S1. Weld the outer edges of the top layer (2) and the bottom layer (3) to the reinforcing strip (4a), trim and control the corresponding size of the reinforcing strip (4a), and then place it on the workbench to prepare for the next step. S2. Remove the welded top layer (2) and bottom layer (3) from the workbench and weld the top layer (2) and bottom layer (3) to the wire drawing body (1) to form the mattress body. Then place it on the workbench and cut and control the size of the top layer (2) and bottom layer (3) before preparing for the next step. S3. Remove the mattress body from the workbench and weld one side of the cut surface layer (2) to the outer side of the upper end of the wrapping strip (4) through the reinforcing strip (4a), and weld the other side directly to the inner side of the upper end of the wrapping strip (4). S4. Weld the outer side of the lower end of the shroud (4) to the reinforcing strip (4a) located in the bottom layer (3), and weld the inner side of the lower end of the shroud (4) directly to the bottom layer (3). After welding, place the finished product on the workbench. S5. After welding the finished upper band (4) to the mattress body and cutting off the excess edges, package it.

2. The manufacturing method of the wire-drawn air mattress according to claim 1, characterized in that, After step S1 is completed and the mattress body is placed on the workbench, check for any leakage or folding and place it in the non-conforming area.

3. The manufacturing method of the wire-drawn air mattress according to claim 1, characterized in that, The reinforcing strip (4a) is welded to the top layer (2) or the bottom layer (3) by a high-frequency welding device, and an external indentation (7) is formed on the reinforcing strip (4a).

4. The manufacturing method of the wire-drawn air mattress according to claim 1, characterized in that, In step S2, after the surface layer (2) and the bottom layer (3) are laid flat, the wire drawing body (1) is welded to the surface layer (2) and the bottom layer (3) through a high-frequency welding device, and an inner indentation (8) is formed on both the surface layer (2) and the bottom layer (3).

5. The method for manufacturing the wire-drawn air mattress according to claim 1, characterized in that, Before step S3, draw lines on the shroud (4) and fix the air nozzle (6) to the shroud (4). Then, open the electric pump (5) hole (4b) on the shroud (4) and press the electric pump (5) into the mold.

6. The method for manufacturing the wire-drawn air mattress according to claim 5, characterized in that, After the band (4) is cut, the positions where holes need to be made are marked and lines are drawn. The air nozzle (6) is passed through the band (4) and welded. After cooling, the band (4) with the air nozzle (6) is placed on the workbench with the side of the air nozzle (6) with the pull ring (6a) facing outward.

7. The method for manufacturing the wire-drawn air mattress according to claim 6, characterized in that, Remove the shroud (4) from the workbench and make a hole (4b) for the electric pump (5) on the shroud (4). Then use a mold to fix the electric pump (5) on the shroud (4) through the hole (4b).

8. The method for manufacturing the wire-drawn air mattress according to claim 1, characterized in that, In step S5, before removing the excess edge, check for any appearance defects on the workbench, and take a sample for testing after removing the excess edge.

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