Air cushion and welding equipment and welding method thereof

Abstract

The invention relates to the field of high-frequency welding machines, in particular to an air cushion and welding equipment and method thereof.The air cushion comprises an upper-layer material, a lower-layer material and a plurality of hollow ventilation guide pipes arranged between the upper-layer material and the lower-layer material, and the ventilation guide pipes penetrate through the thickness direction of the air cushion to form through holes; an upper flange and a lower flange which extend inwards in the radial direction are arranged at the two ends of each ventilation guide pipe respectively, the upper flanges are welded to the upper-layer material, and the lower flanges are welded to the lower-layer material. According to the welding equipment and the welding method, the ventilation guide pipe is arranged on the outer side of the core mold in a sleeving mode in advance, then the two electrode modules are used for clamping the core mold up and down for welding, and the ventilation guide pipe, the upper-layer material and the lower-layer material are welded into a whole in the mode that the core mold is taken out after welding. According to the embodiment of the invention, the problem of through hole deformation after the thick air cushion is inflated is fundamentally solved, and meanwhile, the three steps of welding, trepanning and waste material removal are integrated into an automatic action.

Description

Technical Field

[0001] The present invention relates to the field of high-frequency welding machines, and particularly to an air cushion, its welding equipment, and a welding method. Background Art

[0002] In the prior art, an air cushion with a ventilation function usually has a series of through-holes penetrating its thickness direction and distributed in a rectangular array as air flow channels. Its mainstream production method is: adopting high-frequency welding technology, and using a circular electrode to weld the upper and lower layer materials of the air cushion together to form a circular welding zone. Subsequently, the materials inside the welding zone are punched to form through-holes.

[0003] However, this traditional process has a significant defect: it limits the effective thickness of the air cushion. When the air cushion is designed to be relatively thick, the materials at the edges of the through-holes will undergo obvious shrinkage and deformation due to tension after inflation, affecting the regularity, aesthetics, and ventilation effect of the through-holes, and even possibly causing structural damage. Summary of the Invention

[0004] The purpose of the present invention is to provide an air cushion, its welding equipment, and a welding method to solve the problem that it is difficult to produce an air cushion with a certain thickness and having a series of through-holes penetrating its thickness direction and distributed in a rectangular array by traditional processes.

[0005] To solve the above technical problems, the present invention specifically provides the following technical solutions: An air cushion, comprising: an upper layer material and a lower layer material, and a plurality of hollow ventilation ducts disposed between the upper layer material and the lower layer material. The ventilation ducts penetrate the thickness direction of the air cushion to form through-holes. Each end of each ventilation duct has an upper flange and a lower flange extending radially inward. The upper flange is welded to the upper layer material, and the lower flange is welded to the lower layer material.

[0006] Further, the ventilation ducts and the upper and lower flanges are of an integral structure.

[0007] Further, the cross-section of the through-holes and the ventilation ducts is elliptical, and the axial length of the ventilation ducts is greater than the length of the major axis of its own cross-section.

[0008] A welding device for an air cushion, the welding device being used for producing an air cushion, the welding device including an upper flat plate, a lower flat plate, a core mold located between the two, and electrode modules symmetrically installed on the upper flat plate and the lower flat plate respectively; wherein, the end face of the electrode module facing the welding area includes: a flat seam welding part located on the outer circle, used for forming a high-strength permanent weld; a tear seam welding part located on the inner circle, arranged inside the flat seam welding part, used for forming a weld line that is easy to tear; the core mold is a flat column with an elliptical cross-section, the thickness of the core mold is less than its minor axis dimension, both ends of the core mold are designed with elliptical annular platforms, the elliptical annular platforms are used to provide support for the electrode module when welding the upper material and the lower material, a first vacuum pumping groove recessed inward is arranged at one end of the core mold, a first vacuum pumping air nozzle connecting the first vacuum pumping groove is arranged at the other end of the core mold, and a one-way air valve is arranged inside the first vacuum pumping air nozzle, and the one-way air valve does not allow air to flow from the first vacuum pumping groove to the first vacuum pumping air nozzle.

[0009] Further, the end face of the electrode module further includes a second vacuum pumping groove arranged in the inner side area of the tear seam welding part, and a second vacuum pumping air nozzle communicated with the second vacuum pumping groove, and the second vacuum pumping air nozzle is connected to a vacuum pump so that the second vacuum pumping groove can adsorb waste during the welding process.

[0010] Further, the welding device further includes a bracket for positioning a plurality of prefabricated components, the prefabricated components are core molds pre-sleeved with a sleeve bag, the sleeve bag is a precursor of a ventilation duct, and the bracket has a clamping structure matching the card slot on the outer wall of the core mold to fix the prefabricated components on the lower flat plate.

[0011] A welding method for an air cushion, the welding method is used to manufacture an air cushion, the welding method is executed by a welding device, and the welding method includes the following steps: Step 1. Cloth laying: Place the upper material and the lower material of the air cushion above and below a fixed prefabricated component array respectively. The prefabricated component is a core mold wrapped with a sleeve bag; Step 2. Welding: Start the hydraulic press, and the two electrode modules above and below the prefabricated component are closed. The end face of each electrode module is designed with two concentric elliptical ring-shaped welding parts. Among them, the outer ring is a flat seam welding part for performing high-strength permanent welding on the air cushion material, the top wall of the sleeve bag, and the lower flange, and the inner ring is a tear seam welding part for forming a prefabricated tear line that is easy to tear; Step 3. Synchronous vacuum waste suction: Inside the tear seam welding part, second vacuum suction grooves and second vacuum suction nozzles are respectively arranged at both ends of the electrode module. The second vacuum suction groove fits the upper material or the lower material, and the second vacuum suction nozzle is connected to an external vacuum pump. During welding, the vacuum pump is started, and the material inside the tear seam is adsorbed on the electrode surface through this vacuum groove; Step 4. Die opening and hole forming: After welding is completed, the mold is opened. Since the waste is vacuum adsorbed on the electrode module, as the electrode module rises, the waste is torn off along the preset tear seam, and the upper flange is formed at the originally closed top end of the sleeve bag.

[0012] Further, the welding method further includes the following steps: Step 5. Remove the core mold: After welding and cooling are completed, the air cushion is formed, and a through hole with the upper flange and the lower flange supported by the ventilation duct is formed inside. At this time, rotate the core mold 90 degrees around a horizontal axis passing through its center inside the ventilation duct, and then rotate 90 degrees around another vertical horizontal axis, and the core mold can be removed from the upper flange or the lower flange.

[0013] Furthermore, the welding method further includes a prefabrication process, and the prefabrication process includes the following steps: Step 1. Assembly: Insert the core mold into the opening of the lower flange of the sleeve bag, and rotate it at a certain angle inside the sleeve bag so that the bottom wall of the core mold fits the inner wall of the lower flange of the sleeve bag.

[0014] Furthermore, the prefabrication process further includes the following steps: Step 2. Vacuum adsorption to form a prefabricated component: After placing the core mold inside the sleeve bag, place it on the table of a vacuum extraction device. The vacuum extraction device includes a vacuum extraction tube. When the vacuum extraction tube is inserted into the first vacuum suction nozzle, it can push open the one-way air valve and extract the air inside the sleeve bag. Under the action of vacuum negative pressure, the flexible peripheral wall of the sleeve bag is compressed. At the same time, the inner wall of the closed end of the sleeve bag is closely attached to the elliptical ring-shaped platform at the other end of the core mold.

[0015] The present application has the following beneficial effects compared with the prior art: Through the built-in ventilation duct structure in the embodiments of the present invention, the problem of through-hole deformation after inflation of the thick air cushion is fundamentally solved. At the same time, the three steps of welding, hole opening, and waste removal are integrated into one automated operation, greatly improving the production efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following will briefly introduce the drawings required for use in the description of the embodiments or the prior art. Obviously, the drawings in the following description are only exemplary, and for those of ordinary skill in the art, without creative efforts, other implementation drawings can also be obtained according to the provided drawings.

[0017] Figure 1 Top view of the air cushion according to an embodiment of the present invention; Figure 2 Cross-sectional view of the air cushion according to an embodiment of the present invention; Figure 3 Top view of the core mold according to an embodiment of the present invention; Figure 4 Cross-sectional view of the core mold according to an embodiment of the present invention; Figure 5 Stereogram of the core mold from one perspective according to an embodiment of the present invention; Figure 6 Stereogram of the core mold from another perspective according to an embodiment of the present invention; Figure 7 Stereogram of the core mold and the sleeve bag according to an embodiment of the present invention; Figure 8 Cross-sectional view of the core mold, the sleeve bag, and the vacuum pumping device according to an embodiment of the present invention; Figure 9 Side view of the welding device according to an embodiment of the present invention; Figure 10 Stereogram of the lower flat plate according to an embodiment of the present invention; Figure 11 Action diagram of installing the bracket to the lower flat plate according to an embodiment of the present invention; Figure 12 Welding process diagram according to an embodiment of the present invention; Figure 13 Action diagram after welding completion according to an embodiment of the present invention; The reference numerals in the drawings are respectively represented as follows: 1 - Air cushion; 11 - Through hole; 12 - Upper layer material; 13 - Lower layer material; 14 - Ventilation duct; 141 - Upper flange; 142 - Lower flange; 2 - Prefabricated component; 21 - Core mold; 211 - Elliptical annular platform; 212 - First vacuum extraction groove; 213 - First vacuum extraction nozzle; 214 - Check valve; 215 - Card slot; 22 - Sleeve bag; 4 - Vacuum extraction equipment; 41 - Table top; 42 - Vacuum extraction pipe; 5 - Upper flat plate; 6 - Lower flat plate; 61 - Fixture; 7 - Electrode module; 71 - Flat seam welding part; 72 - Tear seam welding part; 73 - Second vacuum extraction groove; 74 - Second vacuum extraction nozzle; 8 - Bracket; 81 - Wavy support rod; 82 - Elliptical clamping structure. Detailed implementation manners

[0018] The following will clearly and completely describe the technical solutions in the embodiments of the present invention with reference to the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts shall fall within the protection scope of the present invention.

[0019] The core purpose of the present invention is to overcome the defects of the prior art and provide a new method and its supporting equipment that can manufacture an air cushion 1 with a relatively large thickness and a stable through hole 11 structure without deformation.

[0020] To achieve this purpose, the present invention proposes an innovative air cushion 1 structure and corresponding manufacturing process.

[0021] (Regarding the air cushion 1) Referring to Figure 2 (Cross-sectional view of the air cushion 1), the upper layer material 12 and the lower layer material 13 of the air cushion 1 of the present invention are not directly welded to form the through hole 11, but are achieved by implanting and welding several prefabricated ventilation ducts 14. Flanges extending radially inward are provided at both ends of each ventilation duct 14. Through high-frequency welding, the upper flange 141 is firmly connected to the upper layer material 12 of the air cushion 1, and the lower flange 142 is firmly connected to the lower layer material 13 of the air cushion 1.

[0022] This structure not only forms a stable air flow path, but more importantly, the ventilation duct 14 itself plays a role of structural support, effectively resisting the internal tension after inflation, ensuring that even in the air cushion 1 with a relatively large thickness, the through hole 11 can maintain its designed shape and size without deformation.

[0023] (Regarding the welding equipment) To efficiently and precisely manufacture the above-mentioned air cushion 1, the present invention designs a manufacturing process including a prefabrication process and a welding process, and develops a special core mold 21 and welding equipment for this purpose.

[0024] Reference Figures 3 to 8 , prefabrication process: vacuum combination of the core mold 21 and the sleeve bag 22.

[0025] The goal of the prefabrication process is to manufacture a standardized prefabricated component 2 (core mold 21 and sleeve bag 22 firmly combined by vacuum action) for subsequent welding.

[0026] Refer to Figure 3 (top view of the core mold 21), Figure 4 (cross-sectional view of the core mold 21), Figure 5 (isometric view of the core mold 21 from one perspective) and Figure 6 (isometric view of the core mold 21 from another perspective).

[0027] The core mold 21 is a flat column with an elliptical cross-section, and its thickness is less than its minor axis dimension. Elliptical annular platforms 211 are designed at both ends of the core mold 21 to support the upper material 12 and the lower material 13 of the air cushion 1 in subsequent processes. A micro vacuum system is integrated inside the core mold 21. The micro vacuum system includes a first vacuum extraction groove 212 that is recessed inward at one end of the core mold 21, and a first vacuum extraction air nozzle 213 that is provided at the other end of the core mold 21. The inside of the first vacuum extraction air nozzle 213 contains a one-way air valve 214, and the one-way air valve 214 does not allow air to flow unidirectionally from the first vacuum extraction groove 212 to the first vacuum extraction air nozzle 213.

[0028] Refer to Figure 7 (isometric view of the core mold 21 and the sleeve bag 22). The sleeve bag 22 is the precursor of the ventilation duct 14, and its shape is an oval cross-section soft bag with one end closed and one end open. Its open end has a radially inward lower flange 142, and its axial length is greater than the major axis of the core mold 21.

[0029] Refer to Figure 7 and Figure 8 (cross-sectional view of the core mold 21, the sleeve bag 22 and the vacuum extraction device 4). The prefabrication process includes the following steps: Step 1. Combination: Insert the core mold 21 through the opening of the lower flange 142 of the sleeve bag 22, and use its elliptical characteristics to rotate a certain angle inside the sleeve bag 22 so that the bottom wall of the core mold 21 (the end with the first vacuum extraction air nozzle 213) fits against the inner wall of the lower flange 142 of the sleeve bag 22.

[0030] Step 2. Vacuum adsorption: Place the core mold 21 into the sleeve bag 22, and then place it on the table 41 of the dedicated vacuum extraction device 4. The vacuum extraction device 4 includes a vacuum extraction tube 42. When the vacuum extraction tube 42 is inserted into the first vacuum extraction air nozzle 213, it can push open the one-way air valve 214 to extract the air inside the sleeve bag 22.

[0031] Step 3. Molding: Under the action of vacuum negative pressure, the flexible wall of the sleeve bag 22 is tightly compressed and firmly adheres to the outer wall of the core mold 21. At the same time, the inner wall of the closed end of the sleeve bag 22 also closely fits with the elliptical annular platform 211 at the other end of the core mold 21.

[0032] Thus, a core mold 21 and a sleeve bag 22 form a solid and unified prefabricated component 2 through the action of vacuum, preparing for the next welding process.

[0033] Refer to Figures 9 to 13 , welding process: integrated welding and automatic punching.

[0034] The goal of the welding process is to integrate the prefabricated component 2 with the upper material 12 and the lower material 13 of the air cushion 1 into one body, and to automatically form openings on the upper material 12, the lower material 13 of the air cushion 1 and the sleeve bag 22.

[0035] Refer to Figure 9 (side view of the welding equipment), refer to Figure 10 (3D view of the lower flat plate 6) and Figure 11 (action diagram of the bracket 8 installed on the lower flat plate 6), the welding process depends on a new type of welding equipment to execute. The welding equipment includes a hydraulic press and a pressing frame, as well as a special upper flat plate 5, a lower flat plate 6 and an electrode module 7.

[0036] In order to accurately position multiple prefabricated components 2 between the upper flat plate 5 and the lower flat plate 6, the welding equipment includes several brackets 8. The bracket 8 is composed of two symmetric wavy support rods 81. The elliptical engaging structure 82 formed between the two wavy support rods 81 precisely matches the preset card slot 215 on the outer wall of the core mold 21. The two ends of the bracket 8 are fixed by the clamps 61 on the lower flat plate 6, thus constructing a stable rigid array of "lower flat plate 6 - bracket 8 - core mold 21".

[0037] Refer to Figure 12 (welding process) and Figure 13 (end of welding), the welding process includes the following steps.

[0038] Step 1. Cloth laying: Place the upper material 12 and the lower material 13 of the air cushion 1 above and below the fixed array of prefabricated components 2 respectively.

[0039] Step 2. Welding: Start the hydraulic press, and the two electrode modules 7 above and below the prefabricated component 2 are closed. The end face of each electrode module 7 is designed with two concentric elliptical annular welding parts. Among them, the outer ring is a flat seam welding part 71, which is used to perform high-strength permanent welding on the air cushion 1 material and the top wall and the lower flange 142 of the sleeve bag 22 to form a firm sealed flat seam. The inner ring is a tear seam welding part 72, and the welding strength formed by it is lower, which is an easily torn prefabricated tear line.

[0040] Step 3: Synchronous vacuum waste suction: Inside the inner side of the tear seam welding part 72, two ends of the electrode module 7 are respectively provided with a second vacuum pumping groove 73 and a second vacuum pumping nozzle 74. The second vacuum pumping groove 73 is attached to the upper layer material 12 or the lower layer material 13, and the second vacuum pumping nozzle 74 is connected to an external vacuum pump. During welding, the vacuum pump is started, and the materials inside the tear seam (including a small piece of air cushion 1 material and the top material of the sleeve bag 22) are firmly adsorbed on the surface of the electrode module 7 through this vacuum groove.

[0041] Step 4: Die opening and hole forming: After welding is completed, the die is opened. Since the waste material is firmly adsorbed on the electrode module 7 by the vacuum system, as the electrode module 7 rises, the waste material will be cleanly and neatly torn off along the preset tear seam. This ingenious design combines the two steps of "welding" and "hole opening" into one and automatically completes the removal of the waste material. After tearing, the originally closed top end of the sleeve bag 22 forms the upper flange 141.

[0042] Step 5: Removing the core mold 21: After welding and cooling are completed, the air cushion 1 is formed, and a through hole 11 with an upper flange 141 and a lower flange 142 supported by the ventilation duct 14 is formed inside. At this time, taking advantage of the fact that the thickness of the elliptical cross-section of the core mold 21 is less than the minor axis, the core mold 21 can be removed from the ventilation duct 14. Just rotate the core mold 21 90 degrees around a horizontal axis passing through its center inside the duct, and then rotate it 90 degrees around another vertical horizontal axis, so that its posture can be taken out from the elliptical upper flange 141 or lower flange 142 without any obstacles.

[0043] The above embodiments are only exemplary embodiments of the present invention and are not used to limit the present invention. The protection scope of the present invention is defined by the claims. Those skilled in the art can make various modifications or equivalent replacements within the essence and protection scope of the present invention, and such modifications or equivalent replacements should also be regarded as falling within the protection scope of the embodiments of the present invention.

Claims

1. An air cushion, characterized in that, Comprising: an upper layer material (12) and a lower layer material (13), and a plurality of hollow ventilation ducts (14) disposed between the upper layer material (12) and the lower layer material (13), the ventilation ducts (14) penetrating through the thickness direction of the air cushion (1) to form through holes (11), each end of each ventilation duct (14) having an upper flange (141) and a lower flange (142) extending radially inward, the upper flange (141) being welded to the upper layer material (12), and the lower flange (142) being welded to the lower layer material (13).

2. The air cushion according to claim 1, wherein: the ventilation duct (14) and the upper flange (141), lower flange (142) are of an integral structure.

3. The air cushion according to claim 1, wherein: the cross section of the through hole (11) and the ventilation duct (14) is elliptical, and the axial length of the ventilation duct (14) is greater than the length of the major axis of its own cross section.

4. A welding device for an air cushion, wherein: the welding device is used for producing the air cushion according to claim 1, the welding device includes an upper flat plate (5), a lower flat plate (6), a core mold (21) located between the two, and electrode modules (7) symmetrically installed on the upper flat plate (5) and the lower flat plate (6) respectively; wherein, the end face of the electrode module (7) facing the welding area includes: a flat seam welding part (71) located on the outer circle, for forming a high-strength permanent weld; a tear seam welding part (72) located on the inner circle, disposed inside the flat seam welding part (71), for forming a weld line that is easy to tear; the core mold (21) is a flat column with an elliptical cross section, the thickness of the core mold (21) is less than the minor axis dimension of itself, both ends of the core mold (21) are designed with elliptical annular platforms (211), the elliptical annular platforms (211) are used to provide support for the upper layer material (12) and the lower layer material (13) when the electrode module (7) welds them, a first vacuum pumping groove (212) is recessed inward at one end of the core mold (21), a first vacuum pumping nozzle (213) connecting the first vacuum pumping groove (212) is provided at the other end of the core mold (21), a one-way air valve (214) is arranged inside the first vacuum pumping nozzle (213), and the one-way air valve (214) does not allow air to flow from the first vacuum pumping groove (212) to the first vacuum pumping nozzle (213).

5. The welding device according to claim 4, wherein: the end face of the electrode module (7) further includes a second vacuum pumping groove (73) disposed in the inner side area of the tear seam welding part (72), and a second vacuum pumping nozzle (74) communicating with the second vacuum pumping groove (73), and the second vacuum pumping nozzle (74) is connected to a vacuum pump so that the second vacuum pumping groove (73) can adsorb waste during the welding process.

6. The welding device according to claim 5, wherein: The welding device further includes a bracket (8) for positioning a plurality of prefabricated components (2), the prefabricated components (2) being a core mold (21) pre - sleeved with a sleeve bag (22), the sleeve bag (22) being a precursor of the ventilation duct (14), and the bracket (8) having an engaging structure matching the card slot (215) on the outer wall of the core mold (21) to fix the prefabricated components (2) on the lower flat plate (6).

7. A welding method of the welding device according to claim 4, characterized in that the welding method is used to manufacture the air cushion as claimed in claim 1, and the welding method comprises the following steps: Step 1, Cloth laying: Place the upper material (12) and the lower material (13) of the air cushion (1) above and below the array of fixed prefabricated components (2) respectively, the prefabricated components (2) being core molds (21) wrapped with sleeve bags (22); Step 2, Welding: Start the hydraulic press, and the two electrode modules (7) above and below the prefabricated component (2) are closed. The end face of each electrode module (7) is designed with two concentric elliptical - ring - shaped welding parts. Among them, the outer ring is a flat - seam welding part (71) for performing high - strength permanent welding on the air cushion (1) material, the top wall of the sleeve bag (22), and the lower flange (142), and the inner ring is a tear - seam welding part (72) for forming a pre - formed tear line that is easy to tear; Step 3, Synchronous vacuum waste suction: Inside the tear - seam welding part (72), second vacuum pumping grooves (73) and second vacuum pumping nozzles (74) are respectively provided at both ends of the electrode module (7). The second vacuum pumping groove (73) fits against the upper material (12) or the lower material (13), and the second vacuum pumping nozzle (74) is connected to an external vacuum pump. During welding, the vacuum pump is started, and the material inside the tear seam is adsorbed on the electrode surface through this vacuum groove; Step 4, Mold opening and hole forming: After welding is completed, the mold is opened. Since the waste is vacuum - adsorbed on the electrode module (7), as the electrode module (7) rises, the waste is torn off along the preset tear seam, and the originally closed top end of the sleeve bag (22) forms the upper flange (141).

8. According to claim 7, the welding method is characterized in that the welding method further comprises the following steps: Step 5, Removing the core mold (21): After welding and cooling are completed, the air cushion (1) is formed, and a through - hole (11) with an upper flange (141) and a lower flange (142) supported by the ventilation duct (14) is formed inside. At this time, rotate the core mold (21) 90 degrees around a horizontal axis passing through its center inside the ventilation duct (14), and then rotate it 90 degrees around another vertical horizontal axis, and the core mold (21) can be removed from the upper flange (141) or the lower flange (142).

9. According to claim 7, the welding method is characterized in that the welding method further includes a pre - fabrication process, and the pre - fabrication process comprises the following steps: Step 1. Assembly: Insert the core mold (21) through the opening of the lower flange (142) of the sleeve bag (22), and rotate it by a certain angle inside the sleeve bag (22) so that the bottom wall of the core mold (21) fits against the inner wall of the lower flange (142) of the sleeve bag (22).

10. The welding method according to claim 9, wherein the prefabrication process further includes the following steps: Step 2. Vacuum adsorption to form the prefabricated component (2): After placing the core mold (21) inside the sleeve bag (22), place it on the tabletop (41) of the vacuum extraction device (4). The vacuum extraction device (4) includes a vacuum extraction pipe (42). When the vacuum extraction pipe (42) is inserted into the first vacuum extraction air nozzle (213), it can push open the one-way air valve (214) to extract the air inside the sleeve bag (22). Under the action of vacuum negative pressure, the flexible peripheral wall of the sleeve bag (22) is compressed. At the same time, the inner wall of the closed end of the sleeve bag (22) fits tightly against the elliptical annular platform (211) at the other end of the core mold (21).

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