Preparation method of a no-edge air cushion powder puff

Abstract

The application provides a preparation method of a no-edge air cushion powder puff, comprising the following steps: 1) cutting raw materials; 2) hot pressing adhesive film; 3) hot pressing PU skin and fabric; 4) secondary heating; 5) placing at room temperature; 6) stamping, cutting and forming: a new stamping cutter die is adopted, the stamping cutter die moves upward, the horizontal cutting surface on the convex ring-shaped cutter die realizes cutting and separation, then the inward flanging inclined surface on the convex ring-shaped cutter die flanges the fabric in the inward downward direction and flanges the PU skin in the inward upward direction, after the flanging is completed, the upper flat steel plate and the stamping cutter die realize hot pressing to hot-press and bond the fabric and the PU skin together, and the air cushion powder puff is obtained; the hot-pressing mode of the PU skin and the fabric is optimized, the skin feeling at the composite edge becomes smooth and skin-friendly and no residual is exposed, the problem of residual PU skin at the convex edge of the traditional air cushion powder puff is completely solved, and multiple performance problems of the air cushion powder puff in the use process, such as foundation residual, face scratching, makeup dead angle and the like, are solved.

Description

Technical Field

[0001] This invention belongs to the field of cushion puff preparation technology, specifically relating to a method for preparing a borderless cushion puff. Background Technology

[0002] The cushion puff was born alongside the cushion BB cream. Like the beauty blender, the cushion puff represents a revolution in the history of cushion puffs and a major innovation in the beauty and makeup industry. Its ingenuity lies in its structure. The cushion puff is a composite structure, consisting of fabric, elastic sponge, PU leather, and ribbon.

[0003] The traditional cushion puffs currently on the market come in a wide variety of shapes and types, but they all suffer from a persistent flaw that remains unresolved. This flaw has been a challenge for various cushion puff R&D centers. During the cushion puff molding process, the molding process results in a protruding edge at the edge of the puff, approximately 0.5-2mm wide and 0.2-0.5mm thick. This protruding edge is formed during the product molding and pressing process, and it's an unavoidable defect in traditional cushion puff molding. The various components of the cushion puff are forcibly pressed together using a stamping machine. The upper PU leather of the cushion puff needs to wrap around the lower fabric, and then the outline is melted off at high temperature. This results in a protruding PU leather edge at the bonding point after molding. This protruding edge feels hard to the touch, and due to the pressing process, its outer edge is very thin. The defect of the convex edges of this cushion puff during use can cause users to experience issues such as scratching their face, foundation residue, makeup dead spots, poor skin feel at the edges, poor overall appearance of the cushion puff, and failure to achieve the expected flexibility, all of which significantly reduce the user experience. Summary of the Invention

[0004] The purpose of this invention is to provide a method for preparing a borderless cushion puff, so as to completely improve the problem of residue on the outer edge of the contour of the traditional puff from the perspective of molding, completely overcome the molding difficulties, and achieve a complete improvement in the performance and appearance of the puff. This can effectively enhance the intuitive experience of consumers and solve the drawbacks of traditional puff manufacturing.

[0005] To achieve the above objectives, the technical solution of the present invention is as follows:

[0006] A method for preparing a borderless cushion puff includes the following steps performed sequentially:

[0007] 1) Raw material cutting: Cut the PU leather, film, fabric, and sponge to the target length and width dimensions respectively;

[0008] 2) Hot-pressing adhesive film: A layer of adhesive film is hot-pressed onto both sides of the sponge;

[0009] 3) Then, heat-press the PU leather and the fabric onto the outer surface of the adhesive film on both sides of the sponge to obtain the heat-pressed intermediate product.

[0010] In the hot-pressed intermediate product, the fabric, the upper adhesive film, the sponge, the lower adhesive film, and the PU leather are stacked in order from top to bottom. The fabric is bonded to the sponge through the upper adhesive film, and the PU leather is bonded to the sponge through the lower adhesive film.

[0011] 4) The hot-pressed intermediate obtained after hot pressing in step 3) is heated a second time;

[0012] 5) After the intermediate product is heated twice, it should be left at room temperature for a period of time.

[0013] 6) Stamping, cutting and forming: A stamping die is used. The stamping die is a structure with a convex ring die set on the upper surface of the flat steel plate base. The outer diameter of the convex ring die gradually decreases from bottom to top so that the top surface of the convex ring die forms a cutting edge. The top surface of the convex ring die includes a horizontal cutting surface located on the radially outer horizontal plane and an inwardly folding inclined surface located on the radially inner side in the inward and downward direction. A flat steel plate is fixedly set above the stamping die.

[0014] A whole sheet of hot-pressed intermediate product is placed on the stamping die, with the fabric on top and the PU leather on the bottom. Then the stamping die moves upward and collides with the upper flat steel plate to achieve stamping, cutting and forming.

[0015] During the stamping process, the horizontal cutting surface on the convex ring die achieves cutting and separation. Then, under the combined action of the stamping pressure and the extrusion pressure of the inward flanging slope, the inward flanging slope on the convex ring die folds the fabric inward and downward and the PU leather inward and upward. After the flanging is completed, the upper flat steel plate and the stamping die are hot-pressed together to align the thickness of the fabric and the thickness of the PU leather on the side and hot-press them together to form an adhesive surface. This ensures that the thickness of the fabric and the thickness of the PU leather are all folded inward and hot-pressed inside, no longer exposed. After completion, a borderless cushion puff is obtained.

[0016] Preferably, the inner diameter of the convex annular die remains constant from bottom to top, and the convex annular die is also provided with a groove.

[0017] Preferably, the inner diameter surface of the convex annular die is a conical surface, and the inner diameter of the convex annular die gradually decreases from top to bottom. During the stamping process, the air cushion puff in the convex annular die is gradually pressed downward by the stamping force and moves downward. The more the air cushion puff moves downward, the greater the squeezing force of the gradually decreasing inner diameter surface on the air cushion puff becomes. Under the combined action of the stamping force and the squeezing force of the inner diameter surface, the degree to which the fabric and PU leather turn inward increases, further improving the degree of inward turning of the air cushion puff and further achieving a borderless design.

[0018] Preferably, in steps 2) and 3), the hot pressing temperature is 130℃-135℃, the hot pressing pressure is 0.4MPa-0.6MPa, the hot pressing time is 8s-12s, and the left and right delay adjustment range is 2s-5s.

[0019] Preferably, in step 4), the temperature of the secondary heating is 120℃-135℃, and the time of the secondary heating is 8min-12min.

[0020] Preferably, in step 6), the temperature of the upper flat steel plate is 80℃-150℃, the temperature of the stamping die is 35℃-45℃, the stamping pressure is 8MPa-10MPa, and the pressurization time is 8s-12s.

[0021] This application has achieved the following beneficial technical effects:

[0022] The advantage of this invention lies in optimizing the bonding method between PU leather and fabric, changing it to a method where the cushion puff fabric wraps around the PU leather. This completely improves the problem of PU leather residue on the protruding edges of traditional cushion puffs, achieving a borderless cushion puff. This makes the skin feel at the composite edge smooth and skin-friendly with no exposed residue, solving multiple performance problems of cushion puffs during use, such as foundation residue, scratching the face, and makeup dead spots.

[0023] The stability of the edge of the cushion puff has also been greatly improved. Add room temperature purified water to the constant temperature water tank and adjust the temperature to 40℃; take several cushion puffs and put them into the constant temperature water tank to soak completely for 10 minutes; take out the cushion puffs, squeeze out the water, and rub them horizontally and vertically 50 times respectively. The cushion puffs have no cracking, splitting, or delamination.

[0024] Furthermore, this invention is closer to the user's intuitive experience, with a huge improvement in visual appearance, dispelling the user's previous concerns. It also uses a new combination of PU leather and fabric, which has a brand-new significance and breaks through the technical barriers. Attached Figure Description

[0025] Figure 1This is a top view of the stamping die used in the preparation method of a borderless cushion powder puff provided in this application;

[0026] Figure 2 This is a cross-sectional view of the stamping die and the upper flat steel plate in the preparation method of the edgeless cushion powder puff provided in this application. Figure 2 The arrow in the image indicates the upward movement direction of the stamping die. Figure 2 The inner diameter of the convex annular die remains constant from bottom to top.

[0027] Figure 3 yes Figure 2 An enlarged structural diagram of the blade in region A;

[0028] Figure 4 This is a cross-sectional view of the stamping die and the upper flat steel plate in a method for preparing a borderless cushion powder puff according to another embodiment of this application. Figure 4 The inner diameter of the convex annular die gradually decreases from top to bottom, and the angle between the inner diameter surface and the vertical plane is 3°.

[0029] Figure 5 This is a cross-sectional view of the cushion puff prepared by the method for preparing a borderless cushion puff provided in this application.

[0030] In the picture: 101 Fabric, 102 Upper film, 103 Sponge, 104 Lower film, 105 PU leather;

[0031] 2. Stamping die, 201. Convex ring die, 2011. Horizontal cutting surface, 2012. Inwardly turned bevel, 202. Flat steel plate base, 3. Upper flat steel plate. Detailed Implementation

[0032] The technical solutions of the present invention will be clearly and completely described below with reference to the embodiments of the present invention. The described embodiments are only a part of the embodiments of the present invention, and not all of them. Therefore, all other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0033] like Figure 1-5 As shown in the figure: fabric 101, upper adhesive film 102, sponge 103, lower adhesive film 104, PU leather 105; stamping die 2, convex ring die 201, horizontal cutting surface 2011, inwardly turned beveled surface 2012, flat steel plate base 202, upper flat steel plate 3.

[0034] This application provides a method for preparing a borderless cushion puff, comprising the following steps performed in sequence:

[0035] 1) Raw material cutting: Cut the PU leather 105, adhesive film, fabric 101, and sponge 103 to the target length and width dimensions respectively;

[0036] 2) Hot-pressing adhesive film: A layer of adhesive film is hot-pressed onto both sides of the sponge 103;

[0037] 3) Then, heat-press PU leather 105 and fabric 101 onto the outer surface of the adhesive film on both sides of the sponge 103 respectively, and the heat-pressed intermediate product is obtained.

[0038] In the hot-pressed intermediate product, the fabric 101, the upper adhesive film, the sponge 103, the lower adhesive film, and the PU leather 105 are stacked in order from top to bottom. The fabric 101 is bonded to the sponge 103 through the upper adhesive film, and the PU leather 105 is bonded to the sponge 103 through the lower adhesive film.

[0039] 4) The hot-pressed intermediate obtained after hot pressing in step 3) is heated a second time;

[0040] 5) After the intermediate product is heated twice, it should be placed at room temperature (25℃-40℃) for a period of time;

[0041] 6) Stamping, cutting and forming: A stamping die 2 is used. The stamping die 2 is a structure in which a convex annular die 201 is set on the upper surface of the flat steel plate base 202. The outer diameter of the convex annular die 201 gradually decreases from bottom to top so that the top surface of the convex annular die 201 forms a cutting edge. The top surface of the convex annular die 201 includes a horizontal cutting surface 2011 located on the radially outer horizontal plane and an inwardly inclined flange 2012 located on the radially inner side in the inward and downward direction. A flat steel plate 3 is fixedly set on the upper part of the stamping die 2.

[0042] A whole sheet of hot-pressed intermediate product is placed on the stamping die 2, with the fabric 101 on top and the PU leather 105 on the bottom. Then the stamping die 2 moves upward and then collides with the upper flat steel plate 3 to achieve stamping, cutting and forming.

[0043] During the stamping process, the horizontal cutting surface 2011 on the convex ring die 201 cuts and separates the fabric 101. Then, under the combined action of the stamping pressure and the extrusion pressure of the inward flanging surface 2012, the inward flanging surface 2012 on the convex ring die 201 folds the fabric 101 inward and downward and the PU leather 105 inward and upward. After the folding is completed, the upper flat steel plate 3 and the stamping die 2 are hot-pressed together to align the thickness of the fabric 101 to the side and the thickness of the PU leather 105 to the side, and hot-press them together to form an adhesive surface. This ensures that the thickness of the fabric 101 to the side and the thickness of the PU leather 105 to the side are all folded inward and hot-pressed inside, no longer exposed. After completion, a borderless air cushion puff is obtained.

[0044] In one embodiment of this application, the inner diameter of the convex annular die 201 remains constant from bottom to top, and the convex annular die 201 is also provided with a groove.

[0045] In one embodiment of this application, the inner diameter surface of the convex annular die 201 is a conical surface, and the inner diameter of the convex annular die 201 gradually decreases from top to bottom. During the stamping process, the air cushion puff in the convex annular die 201 is gradually pressed downward by the stamping force and moves downward. The more the air cushion puff moves downward, the greater the squeezing force of the gradually decreasing inner diameter surface on the air cushion puff becomes. Under the combined action of the stamping force and the squeezing force of the inner diameter surface, the degree to which the fabric 101 and PU leather 105 turn inward increases, further improving the degree of inward turning of the air cushion puff and further realizing the edgeless design.

[0046] In one embodiment of this application, in steps 2) and 3), the hot pressing temperature is 130℃-135℃, the hot pressing pressure is 0.4MPa-0.6MPa, the hot pressing time is 8s-12s, and the left and right delay adjustment range is 2s-5s.

[0047] In one embodiment of this application, in step 4), the temperature of the secondary heating is 120℃-135℃, and the time of the secondary heating is 8min-12min.

[0048] In one embodiment of this application, in step 6), the temperature of the upper flat steel plate 3 is 80℃-150℃, the temperature of the stamping die 2 is 35℃-45℃, the stamping pressure is 8MPa-10MPa, and the pressurization time is 8s-12s.

[0049] The edgeless molding process of the present invention mainly relies on a new type of molding hydraulic press, high-quality PU leather 105 and fabric 101, and a special die with improved process.

[0050] For edgeless cushion puffs, materials such as PU leather 105, adhesive film, fabric 101, and sponge 103 need to be cut first. The cut size of sponge 103 is 300mm×600mm. The cut size of materials such as PU leather 105, adhesive film, and fabric 101 should be consistent with that of sponge 103, and the cutting tolerance should be within ±5mm.

[0051] Then, the front and back sides of the sponge 103 are pressed together with adhesive film. After pressing, PU leather 105 and fabric 101 are laminated onto the two sides of the sponge 103 respectively. During the lamination process, it should be laid flat in the hot press, and its surface should be kept clean and free from wrinkles, twisting and deformation.

[0052] The hot-pressed composite material is heated a second time to ensure the stability of the material pressing. The material is placed flat in the heating tray with the PU leather 105 side facing up. After the material is heated, it should be placed at room temperature for about 20 minutes before being taken out for molding and stamping to prevent the product from deforming after heating and affecting the quality of the finished product.

[0053] The die in the forming hydraulic press is replaced and adjusted according to the shape required by the customer. A new type of stamping die 2 is used. Then, the heat-sealed material is put into the equipment for test pressing, and the forming effect of the air cushion puff is checked. The equipment parameters, temperature, pressure, forming mold, etc. need to be continuously adjusted for production testing to check whether there are any forming defects, edge bursting, or serious burrs in the product.

[0054] The core innovative technical solution for achieving a borderless cushion puff in this application is as follows:

[0055] (1) This application adds two layers of adhesive film. First, the adhesive film is used to heat-press the fabric 101 and the sponge 103 together, and the adhesive film is used to heat-press the sponge 103 and the PU leather 105 together. The adhesive film has greater adhesion and bonding strength, thereby improving the connection strength between the layers of the cushion puff, making it less prone to delamination, splitting, etc.

[0056] Secondly, during the stamping process, due to the high tensile strength of the adhesive film, the tensile adhesive film holds the fabric 101 and PU leather 105 together, preventing the fabric 101 and PU leather 105 from expanding outwards and turning outwards. The tension applied by the adhesive film makes the fabric 101 and PU leather 105 only shrink inwards and turn inwards. This is very important for achieving edgeless design.

[0057] Thirdly, during the stamping process, after the edge is turned over, due to the excellent hot-pressing bonding ability of the adhesive film, the upper adhesive film after the edge is turned over will be more easily and more powerfully bonded to the sponge 103, the lower adhesive film or PU leather 105 after the edge is turned over, and the lower adhesive film after the edge is turned over will be more easily and more powerfully bonded to the sponge 103, the upper adhesive film or fabric 101 after the edge is turned over. This makes it easier and more powerful for the adhesive film after the edge is turned over to stick to and pull on the other layers after the edge is turned over, thus achieving the maintenance and retention of the edge after the edge is turned over, so that it will not be restored to its original state after the air cushion powder fills the convex ring die 201 after the edge is successfully turned over.

[0058] (2) The stamping die 2 of the existing air cushion puff includes an upper die and a lower die, wherein the upper die moves downward while the lower die is stationary, and the protruding upper die is inserted downward into the lower die to achieve cutting and forming.

[0059] In this application, there is only the lower stamping die 2 (lower die), and no upper die. The upper flat steel plate 3 is just a steel plate with its own heating function, which cannot be considered as the upper die. In addition, the stamping die 2 in this application moves upward.

[0060] In the prior art, the end face of the stamping die 2 is usually horizontal and thin, forming a cutting edge;

[0061] In this application, the top surface of the convex ring die 201 includes a horizontal cutting surface 2011 and an inward flanging slope 2012, for a total of two surfaces. The horizontal cutting surface 2011 is used for cutting and separating, and the inward flanging slope 2012 is used for inward flanging. This application has an additional inward flanging slope 2012.

[0062] In this application, the above-mentioned four structural elements—the lower mold without the upper mold, the upper flat steel plate 3, the convex ring die 201 pressing upwards, the horizontal cutting surface 2011, and the inwardly turned-in inclined surface 2012—work together in a coordinated manner. Each element is indispensable, which enables the inward turning of the fabric 101 and the PU leather 105, ultimately achieving the edgeless design of the cushion puff.

[0063] (3) The above are all structural improvements, but structural improvements alone are not enough to achieve a borderless design. Appropriate process parameters, including temperature and pressure, are also necessary to achieve a borderless design.

[0064] In the existing technology, the temperature of both the upper and lower molds is a high temperature of 120℃-250℃, which forcibly heat-presses the fabric 101 and PU leather 105 together. Due to the high temperature, the originally soft fabric 101 and PU leather 105 are hardened by the heat and become harder. In addition, they protrude outward, thus forming the aforementioned protruding edge with a width of about 0.5-2mm and a thickness of about 0.2-0.5mm. This leads to the aforementioned defects such as the edge scratching the face, foundation residue, makeup dead corners, and poor skin feel at the edge bonding area.

[0065] In this application, the temperature of the upper flat steel plate 3 is reduced to 80℃-150℃, preferably 85℃-95℃, which is already below 100℃. The temperature of the stamping die 2 is reduced to 35℃-45℃. The stamping bonding temperature in step 6) mainly depends on the temperature and heat of the upper flat steel plate 3. The temperature of the stamping die 2 is basically room temperature, so it has little effect on the stamping bonding.

[0066] Due to the excellent hot-pressing bonding performance of the adhesive film, the relatively low temperature of the upper flat steel plate 3 is sufficient to achieve hot-pressing bonding between the upper and lower adhesive films after flanging and the other layers after flanging. Furthermore, the relatively low temperature will not harden the fabric 101 and PU leather 105, allowing the fabric 101 and PU leather 105 to maintain their original soft shape. That is, this application is a low-temperature stamping process, which is very important for achieving a hard edge-free process.

[0067] The key points and protection points of this invention are:

[0068] The edgeless cushion puff can completely change the usage defects of traditional cushion puffs caused by high-temperature molding, bringing a brand-new experience to the product during use;

[0069] The fully automatic computer pressure regulation and temperature control combined with the stamping and hot pressing molding method provides comprehensive technical support for the edgeless process;

[0070] The new forming hydraulic press, combined with the stamping die, ensures efficient integrated forming.

[0071] In this application, the width of the top surface of the convex annular die 201 of the stamping die 2 is 1.0mm-1.5mm, that is, the cutting edge is very thin.

[0072] In this application, PU is an abbreviation for polyurethane, and its chemical name is "polyurethane". PU leather 105 is a type of leather with a polyurethane composition. It is widely used for the decoration of bags, clothing, shoes, vehicles and furniture. It has been increasingly recognized by the market, and its application range is wide, the quantity is large and the variety is many.

[0073] In this application, the adhesive film is preferably a hot melt adhesive film. The adhesive film is a film product with or without release paper, which can be easily operated continuously or intermittently and can be widely used for bonding various fabrics, papers, polymer materials and metals, including PA hot melt adhesive film, PES hot melt adhesive film, PO hot melt adhesive film and medium temperature TPU hot melt adhesive film, etc.

[0074] The methods and apparatus not described in detail in this invention are all prior art and will not be elaborated further.

[0075] To better understand the present invention, the following embodiments are provided for further detailed description of the present invention, but they should not be construed as limiting the present invention. Any non-essential improvements and adjustments made by those skilled in the art based on the above-described invention are also considered to fall within the protection scope of the present invention.

[0076] Example 1

[0077] A method for preparing a borderless cushion puff includes the following steps performed sequentially:

[0078] 1) Raw material cutting: Cut the PU leather 105, adhesive film, fabric 101, and sponge 103 to the target length and width dimensions respectively;

[0079] 2) Hot-pressing adhesive film: A layer of adhesive film is hot-pressed onto both sides of the sponge 103;

[0080] 3) Then, heat-press PU leather 105 and fabric 101 onto the outer surface of the adhesive film on both sides of the sponge 103 respectively, and the heat-pressed intermediate product is obtained.

[0081] In the hot-pressed intermediate product, the fabric 101, the upper adhesive film, the sponge 103, the lower adhesive film, and the PU leather 105 are stacked in order from top to bottom. The fabric 101 is bonded to the sponge 103 through the upper adhesive film, and the PU leather 105 is bonded to the sponge 103 through the lower adhesive film.

[0082] 4) The hot-pressed intermediate obtained after hot pressing in step 3) is heated a second time;

[0083] 5) After the intermediate product is heated twice, it should be left at room temperature for a period of time.

[0084] 6) Stamping, cutting and forming: A stamping die 2 is used. The stamping die 2 is a structure in which a convex annular die 201 is set on the upper surface of the flat steel plate base. The outer diameter of the convex annular die 201 gradually decreases from bottom to top so that the top surface of the convex annular die 201 forms a cutting edge. The top surface of the convex annular die 201 includes a horizontal cutting surface 2011 located on the radially outer horizontal plane and an inwardly inclined flange 2012 located on the radially inner side in the inward and downward direction. A flat steel plate 3 is fixedly set on the upper part of the stamping die 2.

[0085] A whole sheet of hot-pressed intermediate product is placed on the stamping die 2, with the fabric 101 on top and the PU leather 105 on the bottom. Then the stamping die 2 moves upward and then collides with the upper flat steel plate 3 to achieve stamping, cutting and forming.

[0086] During the stamping process, the horizontal cutting surface 2011 on the convex ring die 201 cuts and separates the fabric 101. Then, under the combined action of the stamping pressure and the extrusion pressure of the inward flanging surface 2012, the inward flanging surface 2012 on the convex ring die 201 flangs the fabric 101 inward and downward and the PU leather 105 inward and upward. After the flanging is completed, the upper flat steel plate 3 and the stamping die 2 are hot-pressed together to align the thickness of the fabric 101 to the side and the thickness of the PU leather 105 to the side and hot-press them together to form an adhesive surface. This allows the thickness of the fabric 101 to the side and the thickness of the PU leather 105 to the side to be completely flanged inward and hot-pressed inside, no longer exposed. After completion, a borderless air cushion puff is obtained.

[0087] The inner diameter of the convex ring die 201 remains constant from bottom to top, and the convex ring die 201 is also provided with a groove;

[0088] In steps 2) and 3), the hot pressing temperature is 132℃-134℃, the hot pressing pressure is 0.5MPa, the hot pressing time is 10s, and the left and right delay adjustment interval is 4s.

[0089] In step 4), the temperature for the second heating is 125℃-130℃, and the heating time is 10 minutes.

[0090] In step 6), the temperature of the upper flat steel plate 3 is 95℃, the temperature of the stamping die 2 is 35℃, the stamping pressure is 9MPa, and the pressurization time is 10s.

[0091] Example 2

[0092] A method for preparing a borderless cushion puff includes the following steps performed sequentially:

[0093] 1) Raw material cutting: Cut the PU leather 105, adhesive film, fabric 101, and sponge 103 to the target length and width dimensions respectively;

[0094] 2) Hot-pressing adhesive film: A layer of adhesive film is hot-pressed onto both sides of the sponge 103;

[0095] 3) Then, heat-press PU leather 105 and fabric 101 onto the outer surface of the adhesive film on both sides of the sponge 103 respectively, and the heat-pressed intermediate product is obtained.

[0096] In the hot-pressed intermediate product, the fabric 101, the upper adhesive film, the sponge 103, the lower adhesive film, and the PU leather 105 are stacked in order from top to bottom. The fabric 101 is bonded to the sponge 103 through the upper adhesive film, and the PU leather 105 is bonded to the sponge 103 through the lower adhesive film.

[0097] 4) The hot-pressed intermediate obtained after hot pressing in step 3) is heated a second time;

[0098] 5) After the intermediate product is heated twice, it should be left at room temperature for a period of time.

[0099] 6) Stamping, cutting and forming: A stamping die 2 is used. The stamping die 2 is a structure in which a convex annular die 201 is set on the upper surface of the flat steel plate base. The outer diameter of the convex annular die 201 gradually decreases from bottom to top so that the top surface of the convex annular die 201 forms a cutting edge. The top surface of the convex annular die 201 includes a horizontal cutting surface 2011 located on the radially outer horizontal plane and an inwardly inclined flange 2012 located on the radially inner side in the inward and downward direction. A flat steel plate 3 is fixedly set on the upper part of the stamping die 2.

[0100] A whole sheet of hot-pressed intermediate product is placed on the stamping die 2, with the fabric 101 on top and the PU leather 105 on the bottom. Then the stamping die 2 moves upward and then collides with the upper flat steel plate 3 to achieve stamping, cutting and forming.

[0101] During the stamping process, the horizontal cutting surface 2011 on the convex ring die 201 cuts and separates the fabric 101. Then, under the combined action of the stamping pressure and the extrusion pressure of the inward flanging surface 2012, the inward flanging surface 2012 on the convex ring die 201 folds the fabric 101 inward and downward and the PU leather 105 inward and upward. After the folding is completed, the upper flat steel plate 3 and the stamping die 2 are hot-pressed together to align the thickness of the fabric 101 to the side and the thickness of the PU leather 105 to the side and hot-press them together to form an adhesive surface. This ensures that the thickness of the fabric 101 to the side and the thickness of the PU leather 105 to the side are all folded inward and hot-pressed inside, no longer exposed. After completion, the air cushion puff is obtained.

[0102] The inner diameter surface of the convex annular die 201 is a conical surface. The inner diameter of the convex annular die 201 gradually decreases from top to bottom. During the stamping process, the air cushion puff in the convex annular die 201 is gradually pressed downward by the stamping force and then moves downward. The more the air cushion puff moves downward, the greater the squeezing force of the gradually decreasing inner diameter surface on the air cushion puff becomes. Under the combined action of the stamping force and the squeezing force of the inner diameter surface, the degree of inward folding of the fabric 101 and PU leather 105 becomes greater and greater, further improving the degree of inward folding of the air cushion puff and further realizing the edgeless design.

[0103] In steps 2) and 3), the hot pressing temperature is 132℃-134℃, the hot pressing pressure is 0.6MPa, the hot pressing time is 10s, and the left and right delay adjustment interval is 3s.

[0104] In step 4), the temperature for the second heating is 127℃-132℃, and the heating time is 10 minutes.

[0105] In step 6), the temperature of the upper flat steel plate 3 is 92℃, the temperature of the stamping die 2 is 40℃, the stamping pressure is 9MPa, and the pressurization time is 10s.

[0106] The above description of the disclosed embodiments enables those skilled in the art to make or use the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the invention. Therefore, the invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A method of making a no-edge air cushion puff, characterized in that, The following steps are performed sequentially: 1) Raw material cutting: Cut the PU leather, film, fabric, and sponge to the target length and width dimensions respectively; 2) Hot-pressing adhesive film: A layer of adhesive film is hot-pressed onto both sides of the sponge; 3) Then, heat-press the PU leather and the fabric onto the outer surface of the adhesive film on both sides of the sponge to obtain the heat-pressed intermediate product. In the hot-pressed intermediate product, the fabric, the upper adhesive film, the sponge, the lower adhesive film, and the PU leather are stacked in order from top to bottom. The fabric is bonded to the sponge through the upper adhesive film, and the PU leather is bonded to the sponge through the lower adhesive film. 4) The hot-pressed intermediate obtained after hot pressing in step 3) is heated a second time; 5) After the intermediate product is heated twice, it should be left at room temperature for a period of time. 6) Stamping, cutting and forming: A stamping die is used. The stamping die is a structure with a convex ring die set on the upper surface of the flat steel plate base. The outer diameter of the convex ring die gradually decreases from bottom to top so that the top surface of the convex ring die forms a cutting edge. The top surface of the convex ring die includes a horizontal cutting surface located on the radially outer horizontal plane and an inwardly folding inclined surface located on the radially inner side in the inward and downward direction. A flat steel plate is fixedly set above the stamping die. A whole sheet of hot-pressed intermediate product is placed on the stamping die, with the fabric on top and the PU leather on the bottom. Then the stamping die moves upward and collides with the upper flat steel plate to achieve stamping, cutting and forming. During the stamping process, the horizontal cutting surface on the convex ring die achieves cutting and separation. Then, under the combined action of the stamping force and the extrusion force of the inward flanging slope, the inward flanging slope on the convex ring die folds the fabric inward and downward and the PU leather inward and upward. After the flanging is completed, the upper flat steel plate and the stamping die are hot-pressed together to align the thickness of the fabric and the thickness of the PU leather on the side and hot-press them together to form an adhesive surface. This allows the thickness of the fabric and the thickness of the PU leather to be completely folded inward and hot-pressed inside, no longer exposed. After completion, a borderless air cushion puff is obtained. The inner diameter surface of the convex annular die is conical, and the inner diameter of the convex annular die gradually decreases from top to bottom. During the stamping process, the air cushion puff in the convex annular die is gradually pressed downward by the stamping force and moves downward. The more the air cushion puff moves downward, the greater the squeezing force of the gradually decreasing inner diameter surface on the air cushion puff becomes. Under the combined action of the stamping force and the squeezing force of the inner diameter surface, the degree to which the fabric and PU leather turn inward increases, further improving the degree of inward turning of the air cushion puff and further achieving a borderless design.

2. The method for preparing a borderless cushion puff according to claim 1, characterized in that, In steps 2) and 3), the temperature of the heat lamination is 130°C 135°C, and the pressure of the heat lamination is 0.4 MPa 0.6 MPa, hot pressing time is 8 s 12s, with a left and right delay adjustment interval of 2s. 5s.

3. The method for preparing a borderless cushion puff according to claim 1, characterized in that, In step 4), the temperature for the second heating is 120℃. 135℃, reheating time is 8 minutes 12 minutes.

4. The method for preparing a borderless cushion puff according to claim 1, characterized in that, In step 6), the temperature of the upper steel plate is 80℃. 150℃, the temperature of the stamping die is 35℃ 45℃, stamping pressure 8MPa 10MPa, pressurization time is 8s 12s.

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