A cushion and a method for manufacturing the same, a production device and an application thereof

Abstract

The present application provides a kind of cushion and its preparation method, production device and application, the preparation method of cushion includes the following steps: take chemical raw materials in molten state injection forming mould, after leveling and standing, demoulding obtains sheet-shaped product embryo material;Take the sheet-shaped product embryo material prepared in step S1 It is placed in blowing system, respectively on the surface of product embryo material heating and product embryo material bottom surface cooling, form the surface of semi-solidified product embryo material into semi-molten state;Take the semi-solidified product embryo material prepared in step S2 It is placed on clamping assembly, then the surface of semi-solidified product embryo material is treated by wire drawing device, i.e. the cushion with silk structure on the surface can be obtained.Cushion includes silk structure, cushion body and anti-skid structure.Effectively solve the problem that traditional cushion production process is complex, production and manufacturing process is easy to cause water pollution, production cost is high, preparation time is long, and resource waste is easy to cause.

Description

Technical Field

[0001] This invention relates to the field of mat processing technology, specifically to a mat, its preparation method, production apparatus, and applications. Background Technology

[0002] Mats play an important role in our daily lives, and are widely used in various places such as homes, offices, and cars. For example... Figure 13 As shown, traditional tufted mattresses typically consist of a base fabric layer, an adhesive layer, a blanket backing, and an edge banding. The base fabric layer is bonded to the end face of the blanket backing via the adhesive layer, and the edge banding wraps around the perimeter of the blanket backing. However, the production process of traditional tufted mattresses usually requires steps such as crushing and removing impurities from composite chemical raw materials, followed by coarse spinning, fine spinning, dyeing, twisting, winding, yarn loading, weaving, laminating, edge trimming, edge banding, and brushing. Its production process is quite complex, and the manufacturing process easily causes water pollution, thus having a significant impact on the environment. At the same time, the production equipment consumes large amounts of water, electricity, and oil resources during the manufacturing process, and a large transportation capacity is required between process nodes. Therefore, the production cost of mattresses is high, the production time is long, and it easily leads to resource waste. Summary of the Invention

[0003] The purpose of this invention is to provide a mat, its preparation method, production device and application, which effectively solves the problems of complex traditional mat production process, easy water pollution during production, high production cost, long preparation time and easy waste of resources.

[0004] To solve the above-mentioned technical problems, the present invention provides a method for preparing a mat, comprising the following steps:

[0005] S1. Mold shaping: The molten chemical raw material is injected into the molding mold, and after being leveled and placed, it is demolded to obtain a sheet-shaped product blank;

[0006] S2, Secondary heating: The sheet-like product blank prepared in step S1 is placed in the blowing system, and the surface of the product blank is heated and the bottom surface of the product blank is cooled to form a semi-solidified product blank with a semi-molten surface.

[0007] S3, Wire drawing: Take the semi-cured product blank prepared in step S2 and place it on the clamping assembly. Then, use a wire drawing device to draw the surface of the semi-cured product blank to obtain a pad with a filamentous structure on the surface.

[0008] Furthermore, it also includes the following steps:

[0009] S4. Surface flattening: Place the mat prepared in step S3 into the flattening device, and cut off the ends of the filamentous structure on the surface of the mat with the cutting head of the flattening device to obtain a mat with a flat surface.

[0010] S5. Edge trimming: Place the mat prepared in step S4 into the trimming device, and use the trimming shears of the trimming device to trim the edge material around the mat to obtain a flat and beautiful mat.

[0011] Furthermore, the chemical raw materials in step S1 are any one or a combination of polyamide, polypropylene, polyethylene terephthalate, and polybutylene terephthalate.

[0012] Furthermore, step S1 also includes the following sub-steps:

[0013] S11. Heating and melting: Any one or more of the following raw materials, namely polyamide, polypropylene, polyethylene terephthalate and polybutylene terephthalate, are placed in an injection molding device for heating and melting to obtain a viscous flow material; wherein, the heating temperature of the injection molding device is 200℃~300℃.

[0014] S12. Mold assembly: The upper mold base of the mold is fastened to the lower mold base of the mold, so that the upper mold base and the lower mold base are enclosed to form an injection cavity;

[0015] S13. Defoaming molding: After injecting the viscous fluid material prepared in step S11 into the injection cavity formed in step S12, the air bubbles in the viscous fluid material are removed by vibration or vacuum. After standing for one minute, the sheet product blank is demolded.

[0016] Furthermore, step S2 also includes the following sub-steps:

[0017] S21. Cooling and forming: Take the sheet-like product blank prepared in step S1 and place it in the blowing system. Use a cold air blower to blow cold air onto the bottom surface of the product blank to cool and form the sheet-like product blank.

[0018] S22, Melting the surface: The surface of the sheet-like product blank prepared in step S21 is heated and melted for the second time by blowing hot air onto the surface of the sheet-like product blank with a hot air blower, while the bottom surface of the sheet-like product blank is heated and melted by blowing cold air onto the bottom surface of the sheet-like product blank with a semi-molten surface and a solid bottom surface; wherein, the heating temperature of the hot air blower is 120℃~180℃.

[0019] Furthermore, step S3 also includes the following sub-steps:

[0020] S31. Lifting the blank: Take the semi-cured product blank prepared in step S2, fix it with the clamping assembly and place it below the wire drawing device, and lift the semi-cured product blank upward using the lifting device.

[0021] S32, Wire drawing: The suction head of the wire drawing device picks up the semi-molten chemical raw material on the surface of the semi-cured product blank that was lifted in step S31, and uses the lifting device to move the semi-cured product blank downward and stretch it, so that the semi-molten chemical raw material is stretched to the side away from the surface of the semi-cured product blank to form a filament structure.

[0022] Furthermore, step S3 also includes the following sub-steps:

[0023] S3-1, Raw material intake: Take the semi-cured product blank prepared in step S2, fix it with the clamping assembly and place it under the wire drawing device, move the wire drawing device downward toward the semi-cured product blank, and take the semi-molten chemical raw material on the surface of the semi-cured product blank through the suction head of the wire drawing device.

[0024] S3-2, Wire drawing: After taking the semi-molten chemical raw material obtained in step S32-1, the wire drawing device is moved upward to stretch the semi-molten chemical raw material to the side away from the surface of the semi-cured product blank, forming a filament structure.

[0025] Furthermore, another embodiment of the present invention provides a production apparatus for preparing mats, wherein a feeder, an injection molding device, a blowing system, a wire drawing device, a flattening device, and a shearing device are arranged sequentially along the direction of chemical raw material conveying;

[0026] The discharge port of the feeder is positioned opposite to the feed port of the injection molding device. The injection molding device is connected to a first transmission mechanism for conveying sheet-shaped product blanks to the blowing system. The feed end of the first transmission mechanism is located inside the injection molding device, and its discharge end extends along the side away from the injection molding device and passes through the blowing system. A second transmission mechanism is connected between the wire drawing device and the flattening device, and the second transmission mechanism passes through the wire drawing device and the flattening device. The feed end of the second transmission mechanism is connected to the discharge end of the first transmission mechanism, and the shearing device is located on one side of the discharge end of the second transmission mechanism.

[0027] The injection molding apparatus includes an injection molding machine and a molding die. The feed hopper of the injection molding machine is positioned opposite to the discharge port of the feed machine. The molding die is located inside the injection molding machine and is used to fix the viscous flow material prepared by the injection molding machine into a fixed shape.

[0028] Furthermore, the molding die includes an upper mold base and a lower mold base, which are fastened together and form an injection cavity between them.

[0029] Furthermore, the injection cavity includes a molding space and two side wing spaces, which are located on both sides of the molding space and are interconnected with the molding space.

[0030] Furthermore, several grooves are provided on the surface of the lower mold base.

[0031] Furthermore, the blowing system includes a hot air blower and a cold air blower, with the hot air blower positioned above the first transmission mechanism and the cold air blower positioned below the first transmission mechanism.

[0032] Furthermore, the wire drawing device includes a vacuum machine, an air extraction pipe, a suction head, and a clamping assembly. The suction head is connected to the vacuum machine through the air extraction pipe. The clamping assembly includes a first clamping arm and a second clamping arm, which are arranged correspondingly to each other.

[0033] Furthermore, another embodiment of the present invention provides a mat, including a filamentous structure, a mat body, and an anti-slip structure, wherein the filamentous structure and the anti-slip structure are respectively located on the upper and lower end faces of the mat body, and the filamentous structure, the mat body, and the anti-slip structure are integrally formed.

[0034] Furthermore, another embodiment of the present invention provides an application of a mat, which is used in car floor mats, car seat cushions, household floor mats, and household seat cushion products.

[0035] Compared with the prior art, the technical solution provided by this invention has the following advantages:

[0036] (1) This invention produces mats using a method that eliminates the need for multiple complex processes, significantly shortening production time, increasing efficiency, and reducing costs. Furthermore, since dyeing and crushing processes are unnecessary, water and air pollution are avoided. This effectively solves the problems of complex traditional mat production processes, which are prone to water pollution, high production costs, long preparation times, and resource waste.

[0037] (2) The present invention uses nylon as a material to make the mat, which greatly reduces the production cost compared with the composite materials used in the traditional manufacturing process. Moreover, the mat made of nylon has excellent durability and softness.

[0038] (3) In the mold shaping process, the present invention can effectively prevent the breakage of the wire in the subsequent wire drawing process by removing the air bubbles in the viscous flow material, thus affecting the product structure and quality.

[0039] (4) In the step of cutting off the ends and scraps of the filamentous structure on the surface of the pad, the cut-off ends and scraps can be recycled, which greatly improves the utilization rate of resources and reduces production costs. Attached Figure Description

[0040] To more clearly illustrate the technical solutions of the prior art and the embodiments of this application, the drawings used in the description of the prior art and the embodiments of this application will be briefly introduced below. Obviously, the drawings described below are only some embodiments recorded in this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0041] Figure 1 This is a flowchart illustrating the manufacturing method of the mat of the present invention.

[0042] Figure 2 This is a schematic diagram of a production apparatus for preparing mats, as shown in Example 3.

[0043] Figure 3 This is a schematic diagram of the molding die in Example 3.

[0044] Figure 4 This is a schematic diagram of the mold shaping process in Example 3.

[0045] Figure 5 This is a schematic diagram of the secondary heating process of the blower system in Example 3.

[0046] Figure 6 For this Figure 5 Cross-sectional view.

[0047] Figure 7 This is a schematic diagram of the wire drawing device used in Example 3 for wire drawing and forming.

[0048] Figure 8 for Figure 7 Cross-sectional view.

[0049] Figure 9 This is a schematic diagram of the surface flattening device used in Example 3.

[0050] Figure 10 for Figure 9 Cross-sectional view.

[0051] Figure 11 This is a schematic diagram of the cutting device in Example 3 cutting edge material.

[0052] Figure 12 This is a schematic diagram of the structure of a mat in Example 4.

[0053] Figure 13 This is a schematic diagram of a traditional tufted foot pad structure.

[0054] Explanation of reference numerals in the attached drawings: Feeder 100, Injection molding device 200, Molding mold 210, Upper mold base 211, Lower mold base 212, Blowing system 300, Hot air blower 310, Cold air blower 320, Wire drawing device 400, First clamping arm 410, Second clamping arm 420, Cutting device 500, Shearing device 600, First transmission mechanism 700, Second transmission mechanism 800, Mat 900, Filament structure 910, Mat body 920, Anti-slip structure 930, Base fabric layer 10, Adhesive layer 20, Blanket bottom 30, Edge binding strip 40. Detailed Implementation

[0055] To better understand the purpose, structure, and function of this invention, the following detailed description, in conjunction with the accompanying drawings, provides a mat, its preparation method, production apparatus, and applications.

[0056] Example 1

[0057] Please see Figure 1 As shown, this embodiment provides a method for preparing a mat, including the following steps:

[0058] S1. Mold Shaping: Molten chemical raw materials are injected into a molding mold. After leveling and allowing to settle, the product blank is demolded to obtain a sheet-like product blank. The chemical raw materials are any one or more combinations of polyamide, polypropylene, polyethylene terephthalate, and polybutylene terephthalate. Preferably, polyamide, i.e., nylon, is used as the chemical raw material. Compared to the composite materials used in traditional manufacturing processes, this significantly reduces production costs, and mats made of nylon have excellent durability and softness. The specific steps include the following:

[0059] S11. Heating and Melting: Any one or more of the following raw materials—polyamide, polypropylene, polyethylene terephthalate, and polybutylene terephthalate—are placed in an injection molding apparatus and heated and melted to obtain a viscous flow material; wherein the heating temperature of the injection molding apparatus is 200℃~300℃. Preferably, the heating temperature of the injection molding apparatus is 220℃.

[0060] S12. Mold Assembly: The upper mold base is fastened onto the lower mold base, forming an injection cavity between them. The injection cavity has side wing spaces for forming side wings on both sides of the sheet-like product blank, so that the semi-cured product blank after injection molding can be fixed by clamping components during the wire drawing step.

[0061] S13. Defoaming molding: After injecting the viscous fluid material prepared in step S11 into the injection cavity formed in step S12, the air bubbles in the viscous fluid material are removed by vibration or vacuum. After standing for one minute, the sheet product blank is demolded.

[0062] It should be noted that in step S13, air bubbles are removed from the viscous raw material using vibration or vacuum. Vibration removes air bubbles by using a common cam mechanism to vibrate the platform or container. The viscous raw material sinks under gravity, while the air, with its lower density, floats, thus removing the air bubbles. Vacuum removes air bubbles by using a vacuum pump to evacuate the air from the sealed space, creating a pressure difference between the inside and outside of the viscous raw material. Air flows from high pressure to low pressure, thus removing the air. Furthermore, removing air bubbles from the viscous raw material effectively prevents filament breakage during subsequent fiber drawing, which would affect the product structure and quality.

[0063] S2. Secondary Heating: The product blank prepared in step S1 is placed in a blowing system, and the surface of the product blank is heated while the bottom surface is cooled, forming a semi-solidified product blank with a semi-molten surface. This includes the following sub-steps:

[0064] S21. Cooling and molding: The product blank prepared in step S1 is placed in the blowing system, and cold air is blown onto the bottom surface of the sheet product blank by the cold air blower to cool and mold the sheet product blank.

[0065] It should be noted that before blowing hot air onto the surface of the sheet product blank in step S22, the cold air blower continuously blows cold air onto the bottom of the product blank to cool and solidify the bottom of the product blank.

[0066] S22. Melting the Surface: The surface of the sheet-like product blank prepared in step S21 is heated and melted a second time by blowing hot air onto the surface of the sheet-like product blank using a hot air blower, while cold air is blown onto the bottom surface of the sheet-like product blank using a cold air blower, resulting in a semi-cured product blank with a semi-molten surface and a solid bottom; wherein the heating temperature of the hot air blower is 120℃~180℃. As a preferred embodiment, the heating temperature of the hot air blower is 150℃. In addition, while blowing hot air onto the surface of the sheet-like product blank prepared in step S21, cold air is blown onto the bottom surface of the sheet-like product blank using a cold air blower, so that the bottom surface of the sheet-like product blank can maintain its original shape and is not affected by the melting and deformation of the hot air.

[0067] S3. Wire Drawing and Shaping: Place the semi-cured product blank prepared in step S2 onto the clamping assembly, and then use a wire drawing device to draw the surface of the semi-cured product blank into wires to obtain a pad with a filamentous structure on the surface. Specifically, this includes the following sub-steps:

[0068] S31. Lifting the blank: Take the semi-cured product blank prepared in step S2, fix it with the clamping assembly and place it below the wire drawing device, and lift the semi-cured product blank upward using the lifting device.

[0069] S32, Fiber Forming: The suction head of the fiber forming device picks up the semi-molten chemical raw material from the surface of the semi-cured product blank raised in step S31, and uses a lifting device to move and stretch the semi-cured product blank downwards, causing the semi-molten chemical raw material to be stretched away from the surface of the semi-cured product blank to form a filamentous structure. To prevent the semi-cured product blank from shifting during the fiber forming process and affecting the fiber forming effect, it is fixed by a clamping assembly.

[0070] First, the semi-cured product blank prepared in step S2 is placed on the transmission mechanism, allowing it to move stepwise with the mechanism. When the semi-cured product blank moves below the drawing device, a lifting device lifts it towards the drawing device. The drawing device then begins operation, sucking up the semi-molten chemical material from the surface of the semi-cured product blank through a suction head. The lifting device then descends to its original height, pulling the semi-cured product blank downwards. This stretches the semi-molten chemical material away from the surface of the semi-cured product blank, forming a filamentous structure. The surface temperature of the filamentous structure dissipates into the air, rapidly cooling and solidifying. Next, the transmission mechanism continues to move the semi-cured product blank forward stepwise. Each time it moves, the lifting device repeats the lifting or lowering operation, while the drawing device repeats the operation of sucking up the semi-molten chemical material from the surface of the semi-cured product blank, until rows of filamentous structures are formed on the surface of the semi-cured product.

[0071] S4. Surface flattening: Place the mat prepared in step S3 into the flattening device, and cut off the ends of the filamentous structure on the surface of the mat with the cutting head of the flattening device to obtain a mat with a flat surface.

[0072] S5. Edge trimming: Place the mat prepared in step S4 into the trimming device, and use the trimming shears of the trimming device to cut off the edge material around the mat, resulting in a flat and aesthetically pleasing mat. The cut-off ends and scraps can be recycled, greatly improving resource utilization and reducing production costs.

[0073] In summary, this manufacturing process eliminates the need for numerous complex steps in mat production, significantly reducing production time, increasing efficiency, and lowering costs. Furthermore, since dyeing and crushing processes are unnecessary, it avoids water and air pollution. This effectively solves the problems of complex traditional mat manufacturing processes, which are prone to water pollution, high costs, long production times, and resource waste. Moreover, the use of nylon as the primary raw material, compared to the composite materials used in traditional processes, greatly reduces production costs, and nylon mats offer excellent durability and softness. Additionally, the mold-forming step, by removing air bubbles from the viscous raw material, effectively prevents filament breakage during subsequent drawing, thus maintaining product structure and quality. Finally, the trimming of the mat's surface filaments and scraps allows for recycling, significantly improving resource utilization and reducing production costs.

[0074] Example 2

[0075] Please see Figure 1 As shown, this embodiment provides a method for manufacturing a mat, which differs from Embodiment 1 only in that step S3 includes the following sub-steps.

[0076] S3-1, Raw material intake: Take the semi-cured product blank prepared in step S2, fix it with the clamping assembly and place it under the wire drawing device, move the wire drawing device downward toward the semi-cured product blank, and take the semi-molten chemical raw material on the surface of the semi-cured product blank through the suction head of the wire drawing device.

[0077] S3-2, Wire drawing: After taking the semi-molten chemical raw material obtained in step S32-1, the wire drawing device is moved upward to stretch the semi-molten chemical raw material to the side away from the surface of the semi-cured product blank, forming a filament structure.

[0078] First, the semi-cured product blank prepared in step S2 is placed on the transmission mechanism, allowing it to move stepwise with the mechanism. When the semi-cured product blank reaches below the drawing device, the drawing device begins operation, moving stepwise downwards towards the semi-cured product blank and then stepwise upwards through the suction head to draw the semi-molten chemical material from the surface of the semi-cured product blank. This stretches the semi-molten chemical material away from the surface of the semi-cured product blank, forming a filamentous structure. The surface temperature of the filamentous structure dissipates into the air, causing it to cool and solidify rapidly. Next, the transmission mechanism continues to move the semi-cured product blank forward, and with each movement, the drawing device repeats the operation of drawing the semi-molten chemical material from the surface of the semi-cured product blank until rows of filamentous structures are formed on the surface of the semi-cured product.

[0079] Example 3

[0080] Please see Figures 2 to 12 As shown, this embodiment provides a production apparatus for preparing the above-mentioned mat, which includes a feeder 100, an injection molding device 200, a blowing system 300, a wire drawing device 400, a flattening device 500, and a shearing device 600 arranged sequentially in the direction of chemical raw material conveying.

[0081] The discharge port of the feeder 100 is positioned opposite to the feed port of the injection molding device 200. The injection molding device 200 is connected to a first transmission mechanism 700 for conveying sheet-shaped product blanks to the blowing system. The feed end of the first transmission mechanism is located inside the injection molding device, and its discharge end extends along the side away from the injection molding device and passes through the blowing system 300. A second transmission mechanism 800 is connected between the wire drawing device 400 and the flattening device 500. The second transmission mechanism 800 passes through the wire drawing device 400 and the flattening device 500. The feed end of the second transmission mechanism 800 is connected to the discharge end of the first transmission mechanism 700, and the shearing device 600 is located on one side of the discharge end of the second transmission mechanism 800.

[0082] The injection molding apparatus 200 includes an injection molding machine and a molding die 210. The feed hopper of the injection molding machine is positioned opposite to the discharge port of the feeder 100. The molding die 210 is located inside the injection molding machine and is used to fix the molten chemical raw materials prepared by the injection molding machine into a fixed shape.

[0083] Specifically, the feeder 100 is used to transfer chemical raw materials for preparing the mat to the injection molding apparatus 200.

[0084] The injection molding device 200 is used to heat and melt the chemical raw materials for preparing the mat into a molten state, and inject the molten chemical raw materials into the molding mold 210. After leveling the molding mold 210 and letting it stand for one minute, the mold is demolded to obtain a sheet product blank, and the sheet product blank is placed on the feeding end of the first transmission mechanism by a robot arm.

[0085] The first transmission mechanism 700 is used to convey sheet-shaped product blanks into the blowing system.

[0086] The blowing system 300 is used to blow hot air onto the surface of the sheet-like product blank on the first transmission mechanism and to blow cold air onto its bottom surface.

[0087] The second transmission mechanism 800 is used to transfer the semi-cured product blank after passing through the blowing system to the wire drawing device.

[0088] The drawing device 400 is used to draw and draw the semi-molten chemical raw materials on the surface of the semi-cured product blank, so that rows of filamentous structures 910 are formed on the surface of the semi-cured product blank, thereby obtaining a pad 900 with filamentous structures 910.

[0089] The flattening device 500 is used to cut off the ends of the filamentous structure 910, so that the filamentous structure 910 on the surface of the pad 900 is flat.

[0090] The cutting device 600 is used to cut off the edge material around the pad 900 with the filamentous structure 910, so that the surface of the pad 900 is neat and beautiful.

[0091] In a preferred embodiment, the molding die 210 includes an upper mold base 211 and a lower mold base 212, the upper mold base 211 and the lower mold base 212 are fastened together, and an injection cavity is formed between the upper mold base 211 and the lower mold base 212.

[0092] Specifically, the injection cavity is used to hold the molten chemical raw materials prepared by the injection molding machine and to form a sheet-like product blank with a certain shape.

[0093] In a preferred embodiment, the injection cavity includes a molding space and two side wing spaces, which are located on both sides of the molding space and are interconnected with the molding space.

[0094] Specifically, the two side wing spaces are used to form side wings on both sides of the sheet-like product blank, so that the semi-cured product blank can be fixed by the clamping components during the wire drawing process.

[0095] In a preferred embodiment, a plurality of grooves are provided on the surface of the lower mold base 212.

[0096] Specifically, by setting several grooves on the surface of the lower mold base, an anti-slip structure 930 is formed on the bottom of the pad 900.

[0097] In a preferred embodiment, the blowing system 300 includes a hot air blower 310 and a cold air blower 320, with the hot air blower 310 positioned above the first transmission mechanism 700 and the cold air blower 320 positioned below the first transmission mechanism 700.

[0098] Specifically, the hot air blower 310 is used to blow hot air onto the surface of the sheet product blank to make its surface semi-molten, and the cold air blower 320 is used to blow cold air onto the bottom of the sheet product blank to cool its bottom and maintain its original shape.

[0099] In a preferred embodiment, the wire drawing device 400 includes a vacuum machine, an air extraction pipe, a suction head, and a clamping assembly. The suction head is connected to the vacuum machine through the air extraction pipe. The clamping assembly includes a first clamping arm 410 and a second clamping arm 420, which are arranged correspondingly to each other.

[0100] Specifically, the vacuum machine is used to evacuate air into the suction pipe so that the suction head can pick up the semi-molten chemical raw materials on the surface of the semi-cured product blank; the clamping assembly is used to clamp the semi-cured product blank, wherein the first clamping arm 410 and the second clamping arm 420 are respectively used to clamp on the two wings of the semi-cured product blank.

[0101] Example 4

[0102] Please see Figure 12 As shown, this embodiment provides a mat, including a filament structure 910, a mat body 920, and an anti-slip structure 930. The filament structure 910 and the anti-slip structure 930 are located on the upper and lower end faces of the mat body 920, respectively, and the filament structure 910, the mat body 920, and the anti-slip structure 930 are integrally formed.

[0103] Specifically, the mat is manufactured using the aforementioned mat preparation method, thus possessing excellent durability and softness. Preferably, the filamentous structure 910 is strip-shaped, and the anti-slip structure 930 can be strip-shaped, conical, or other irregularly shaped.

[0104] In a preferred embodiment, another embodiment of the present invention provides an application of a mat, mat 900 being used in car floor mats, car seat cushions, household floor mats, and household seat cushion products.

[0105] Specifically, the mat is prepared by the above-mentioned mat preparation method, and preferably, the mat 900 is used in car floor mats.

[0106] It is understood that the present invention has been described through some embodiments, and those skilled in the art will recognize that various changes or equivalent substitutions can be made to these features and embodiments without departing from the spirit and scope of the invention. Furthermore, under the teachings of the present invention, these features and embodiments can be modified to adapt to specific situations and materials without departing from the spirit and scope of the invention. Therefore, the present invention is not limited to the specific embodiments disclosed herein, and all embodiments falling within the scope of the claims of this application are within the protection scope of the present invention.

Claims

1. A method for preparing a mat, characterized in that, Includes the following steps: S1. Mold shaping: The molten chemical raw material is injected into the molding mold, and after being leveled and placed, it is demolded to obtain a sheet-shaped product blank; S2, Secondary heating: The sheet-like product blank prepared in step S1 is placed in the blowing system, and the surface of the product blank is heated and the bottom surface of the product blank is cooled to form a semi-solidified product blank with a semi-molten surface. S3, drawing and forming: Take the semi-cured product blank prepared in step S2 and place it on the clamping assembly. Then, draw the surface of the semi-cured product blank with a drawing device to obtain a pad with a filamentous structure on the surface. S4. Surface flattening: Place the mat prepared in step S3 into the flattening device, and cut off the ends of the filamentous structure on the surface of the mat with the cutting head of the flattening device to obtain a mat with a flat surface. S5. Edge trimming: Place the mat prepared in step S4 into the trimming device, and trim the edge material around the mat with the trimming shears of the trimming device to obtain a flat and beautiful mat. Step S3 further includes the following sub-steps: S31. Lifting the blank: Take the semi-cured product blank prepared in step S2, fix it with the clamping assembly and place it below the wire drawing device, and lift the semi-cured product blank upward using the lifting device. S32, Wire drawing: The suction head of the wire drawing device picks up the semi-molten chemical raw material on the surface of the semi-cured product blank that was lifted in step S31, and uses the lifting device to move the semi-cured product blank downward and stretch it, so that the semi-molten chemical raw material is stretched away from the surface of the semi-cured product blank to form a filament structure.

2. The method for preparing the mat according to claim 1, characterized in that, The chemical raw materials in step S1 are any one or a combination of polyamide, polypropylene, polyethylene terephthalate and polybutylene terephthalate.

3. The method for preparing the mat according to claim 2, characterized in that, Step S1 further includes the following sub-steps: S11. Heating and melting: Any one or more of the following raw materials, namely polyamide, polypropylene, polyethylene terephthalate and polybutylene terephthalate, are placed in an injection molding device for heating and melting to obtain a viscous flow material; wherein, the heating temperature of the injection molding device is 200℃~300℃. S12. Mold assembly: The upper mold base of the mold is fastened to the lower mold base of the mold, so that the upper mold base and the lower mold base are enclosed to form an injection cavity; S13. Defoaming molding: After injecting the viscous flow material prepared in step S11 into the injection cavity formed in step S12, the air bubbles in the viscous flow material are removed by vibration or vacuum. After standing for one minute, the product blank is demolded to obtain a sheet-like product blank.

4. The method for preparing the mat according to any one of claims 1 to 3, characterized in that, Step S2 further includes the following sub-steps: S21. Cooling and forming: The sheet-shaped product blank prepared in step S1 is placed in the blowing system, and the bottom surface of the sheet-shaped product blank is blown with cold air by the cold air blower to cool and form the sheet-shaped product blank. S22, Melting the surface: The surface of the sheet-like product blank prepared in step S21 is heated and melted for the second time by blowing hot air onto the surface of the sheet-like product blank with a hot air blower, while the bottom surface of the sheet-like product blank is heated and melted by blowing cold air onto the bottom surface of the sheet-like product blank with a semi-molten surface and a solid bottom surface; wherein, the heating temperature of the hot air blower is 120℃~180℃.

5. The method for preparing the mat according to claim 4, characterized in that, Step S3 further includes the following sub-steps: S3-1, Raw material extraction: Take the semi-cured product blank prepared in step S2, fix it with the clamping assembly and place it under the wire drawing device, move the wire drawing device downward toward the semi-cured product blank, and extract the semi-molten chemical raw material on the surface of the semi-cured product blank through the suction head of the wire drawing device. S3-2, Wire drawing: After taking the semi-molten chemical raw material obtained in step S32-1, the wire drawing device is moved upward to stretch the semi-molten chemical raw material away from the surface of the semi-cured product blank to form a filament structure.

6. A production apparatus for the preparation method according to any one of claims 1 to 5, characterized in that, The feeder, injection molding device, blowing system, wire drawing device, cutting device and shearing device are arranged in sequence along the direction of chemical raw material conveying; The discharge port of the feeder is positioned opposite to the feed port of the injection molding device. The injection molding device is connected to a first transmission mechanism for conveying sheet-shaped product blanks to the blowing system. The feed end of the first transmission mechanism is located inside the injection molding device, and its discharge end extends along the side away from the injection molding device and passes through the blowing system. A second transmission mechanism is connected between the wire drawing device and the flattening device, and the second transmission mechanism passes through the wire drawing device and the flattening device. The feed end of the second transmission mechanism is connected to the discharge end of the first transmission mechanism, and the cutting device is located on one side of the discharge end of the second transmission mechanism. The injection molding apparatus includes an injection molding machine and a molding die. The feed hopper of the injection molding machine is arranged opposite to the discharge port of the feed machine. The molding die is arranged inside the injection molding machine and is used to fix the viscous flow material prepared by the injection molding machine into a fixed shape.

7. The production apparatus according to claim 6, characterized in that, The molding die includes an upper mold base and a lower mold base, the upper mold base and the lower mold base are fastened together, and an injection cavity is formed between the upper mold base and the lower mold base.

8. The production apparatus according to claim 7, characterized in that, The injection cavity includes a molding space and two side wing spaces, which are located on both sides of the molding space and are interconnected with the molding space.

9. The production apparatus according to claim 7, characterized in that, The lower mold base has several grooves on its surface.

10. The production apparatus according to claim 6, characterized in that, The blowing system includes a hot air blower and a cold air blower, with the hot air blower positioned above the first transmission mechanism and the cold air blower positioned below the first transmission mechanism.

11. The production apparatus according to claim 6, characterized in that, The wire drawing device includes a vacuum machine, an air extraction pipe, a suction head, and a clamping assembly. The suction head is connected to the vacuum machine through the air extraction pipe. The clamping assembly includes a first clamping arm and a second clamping arm, which are arranged correspondingly to each other.

12. A mat manufactured by the preparation method according to any one of claims 1 to 5, characterized in that, It includes a filamentous structure, a mat body, and an anti-slip structure. The filamentous structure and the anti-slip structure are located on the upper and lower end faces of the mat body, respectively, and the filamentous structure, the mat body, and the anti-slip structure are integrally formed.

13. An application of the mat according to claim 12, characterized in that, The mats are used in car floor mats, car seat cushions, household floor mats, and household seat cushions.

Images