Inflatable product and manufacturing method thereof

Abstract

The invention relates to the technical field of inflatable products, and discloses an inflatable product which comprises an inflatable base body and a composite layer which is arranged on the inflatable base body and is of a multi-layer structure, and a bonding layer attached to the inflatable base body is arranged on the bottommost layer of the composite layer. By means of the non-glue-joint physical connection technology and the structural design of the composite layer, the problem that in the prior art, the environmental protection property and the air permeability cannot be considered at the same time is effectively solved, the bottom layer of the composite layer is connected with the inflatable base body through the high-frequency high-frequency technology, and the air permeability of the composite layer is improved. The surface layer is provided with a breathable layer such as cotton cloth, natural pores of the breathable layer form an air circulation channel, and the breathable layer is matched with the middle sponge filling layer, so that the contact comfort is improved, and the problem of stuffiness caused by traditional wrapping is solved.

Description

Technical Field

[0001] The present invention relates to the technical field of inflatable products, and in particular to an inflatable product and a manufacturing method thereof. Background Art

[0002] In modern industry and daily life, inflatable products (such as outdoor inflatable mattresses, water buoyancy equipment, etc.) are widely used due to their foldable storage characteristics, but the problem of insufficient comfort has long existed. In order to improve the hard touch and breathability, the industry generally adopts the solution of adding a sponge layer on the surface of the inflatable base. There are currently two main technical paths. One is the direct glue bonding solution, which is to directly stick the sponge layer to the surface of the inflatable base through neoprene, polyurethane glue, etc. Although this method is easy to operate, the glue contains volatile organic compounds such as formaldehyde and benzene. Not only does the production process pollute the environment, but long-term use may also cause harm to human health, and the glue is prone to aging and cracking after curing. Another way is to use a film made of TPU or PVC on the outer layer of the sponge to wrap the sponge layer as a whole on the inflatable matrix. The outer layer of the film is bonded to the inflatable matrix. The dense structure of the membrane in this method will seriously block the air circulation, resulting in poor air permeability of the sponge layer and easy to produce stuffiness. At present, when realizing the connection between the sponge layer and the inflatable matrix, it is impossible to take into account both air permeability and environmental protection requirements. Summary of the Invention

[0003] In view of the deficiencies in the prior art, the present invention provides an inflatable product and a method for manufacturing the same, which realizes the connection between the composite layer and the inflatable matrix through a non-adhesive physical connection process, while solving the problems of environmental protection and air permeability.

[0004] In order to achieve the above object, the present invention adopts the following technical solutions: An inflatable product includes an inflatable base and a composite layer having a multi-layer structure arranged on the inflatable base. The bottom layer of the composite layer is provided with an adhesive layer that is bonded to the inflatable base. The adhesive layer of the composite layer is connected to the inflatable base by a non-adhesive physical connection process. In this solution, the adhesive layer is limited to the bottom layer of the composite layer, and the surface layer is a breathable cotton layer. Air can freely penetrate into the sponge filling layer through the pores of the cotton layer, which can make the composite layer have good air permeability and effectively solve the problem of stuffiness.

[0005] Preferably, the multilayer structure of the composite layer includes a breathable layer, a filling layer and an adhesive layer arranged in sequence. The adhesive layer is a TPU film when used. The adhesive layer can be a TPU film when used. It has good flexibility, weather resistance and compatibility with the inflatable matrix (such as PVC, TPU film), and can achieve reliable connection with the inflatable matrix through subsequent ultrasonic welding and other processes.

[0006] Preferably, the breathable layer, the filling layer and the adhesive layer are stacked to form a composite layer, and the layers of the composite layer are connected by sewing. A connecting layer made of TPU film is provided between the stitched composite layer and the inflatable matrix. The stacked structure enables each composite layer to have a clear division of labor and synergistic effect. The breathable layer is located at the outermost layer and directly contacts the human body, thereby exerting the function of breathability and sweat absorption; the filling layer is located in the middle to provide buffering support; the adhesive layer is located at the bottom layer to achieve connection with the inflatable matrix, and the pinholes caused by sewing can be covered by the connecting layer to avoid a decrease in airtightness or aggravated local wear due to pinholes.

[0007] Preferably, the breathable layer, the filling layer and the adhesive layer are stacked to form a composite layer, and the breathable layer, the filling layer and the adhesive layer are compositely connected by an ultrasonic welding process.

[0008] Preferably, the non-adhesive physical connection process is a high-frequency and high-frequency process, through which the adhesive layer and the surface layer of the inflatable matrix are melted together. The pollution of the existing glue bonding solution comes from the composition characteristics of the chemical adhesive, while the high-frequency and high-frequency process uses a high-frequency electric field to achieve the melting connection of the material itself, without adding any chemical additives, and can avoid the release of harmful substances such as formaldehyde and benzene. It has no health risks to the human body during use and meets environmental protection standards.

[0009] A method for manufacturing an inflatable product, characterized by comprising the following steps: Making a composite layer: stacking the breathable layer, the filling layer, and the adhesive layer in sequence, wherein the adhesive layer can be a TPU film, and prefabricating the three-layer structure into an independent multi-layer composite layer through a fixing process; Composite fixing: the adhesive layer of the composite layer prepared in step 1 is attached to the surface of the inflatable base, and a non-adhesive physical connection process is used to melt-bond and fix the adhesive layer to the surface of the inflatable base.

[0010] Preferably, the fixing process in step 1 is a sewing process, in which the breathable layer, the filling layer and the adhesive layer are sewn together by needle and thread.

[0011] Preferably, the fixing process in step 1 is to compositely connect the breathable layer, the filling layer and the adhesive layer into one body through an ultrasonic welding process.

[0012] Preferably, the non-adhesive physical connection process in step 2 is a high-frequency process.

[0013] Compared with the prior art, the present invention has the following beneficial effects: The present invention effectively solves the problem of environmental protection and breathability that cannot be taken into account at the same time in the existing technology through a non-adhesive physical connection process and a composite layer structure design. The bottom layer of the composite layer is connected to the inflatable matrix through a high-frequency and high-frequency process, without the need for glue, avoiding pollution from volatile organic compounds such as formaldehyde. The production is environmentally friendly and safe to use. A breathable layer such as cotton cloth is provided on the surface, and its natural pores form an air circulation channel. Combined with the middle sponge filling layer, it not only improves contact comfort but also solves the stuffiness problem caused by traditional wrapping. In addition, two composite layer preparation schemes are provided to meet different needs, with flexible processes, standardized step-by-step production and connection processes, and convenient mass production. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the following briefly introduces the drawings required for use in the embodiments. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0015] Figure 1 It is a schematic diagram of the overall structure of the present invention; Figure 2 It is a cross-sectional view of the composite layer of the present invention.

[0016] Explanation of the figure numbers: 1. Breathable layer; 2. Filling layer; 3. Adhesive layer; 4. Inflatable matrix. DETAILED DESCRIPTION

[0017] The present invention will be described in further detail below with reference to the accompanying drawings.

[0018] The following description is intended to disclose the present invention so that those skilled in the art can implement the present invention. The preferred embodiments described below are for illustrative purposes only, and those skilled in the art will readily appreciate other obvious variations. The basic principles of the present invention defined in the following description may be applied to other embodiments, variations, improvements, equivalents, and other technical solutions that do not depart from the spirit and scope of the present invention.

[0019] Those skilled in the art should understand that, in the disclosure of the present invention, the terms "longitudinal", "transverse", "up", "down", "left", "right", "front", "back", "vertical", "horizontal", "top", "bottom", "inside", "outside" and the like to indicate directions or positions are based on the directions or positional relationships shown in the accompanying drawings, which are merely simplified descriptions for the convenience of describing the present invention, and do not indicate or imply that the device or component referred to must have a specific direction, be constructed and operated in a specific direction. Therefore, the above terms should not be understood as limiting the present invention.

[0020] It is to be understood that the term "one" should be understood as "at least one" or "one or more", that is, in one embodiment, the number of an element may be one, while in another embodiment, the number of the elements may be multiple, and the term "one" should not be understood as a limitation on the quantity. Example

[0021] See also Figure 1-2 An inflatable product includes an inflatable base 4 and a composite layer with a multi-layer structure arranged on the inflatable base 4. The bottom layer of the composite layer is provided with an adhesive layer 3 that is in contact with the inflatable base 4. The adhesive layer 3 of the composite layer is connected to the inflatable base 4 through a non-adhesive physical connection process. In this solution, the adhesive layer 3 is limited to the bottom layer of the composite layer, and the surface layer adopts a cotton cloth breathable layer 1. Air can freely penetrate into the sponge filling layer 2 through the pores of the cotton cloth layer, which can make the composite layer have good air permeability and effectively solve the problem of stuffiness.

[0022] The multilayer structure of the composite layer includes a breathable layer 1, a filling layer 2 and an adhesive layer 3 arranged in sequence. The breathable layer 1, the filling layer 2 and the adhesive layer 3 are stacked to form a composite layer. The layers of the composite layer are adaptively connected to each other. The stacked structure makes the composite layers have clear division of labor and synergistic effect. The breathable layer 1 is located at the outermost layer and directly contacts the human body, playing the role of breathability and sweat absorption; the filling layer 2 is located in the middle to provide buffer support; the adhesive layer 3 is located at the bottom layer to achieve connection with the inflatable matrix 4.

[0023] The non-gluing physical connection process is a high-frequency and high-frequency process, through which the adhesive layer 3 and the surface layer of the inflatable matrix 4 are melted together. The pollution of the existing glue bonding solution comes from the composition characteristics of the chemical adhesive, while the high-frequency and high-frequency process uses a high-frequency electric field to achieve the melting connection of the material itself, without the addition of any chemical additives, and can avoid the release of harmful substances such as formaldehyde and benzene. It has no health risks to the human body during use and meets environmental protection standards.

[0024] The breathable layer 1 can be made of cotton, breathable nylon and other materials to improve the contact comfort and breathability of the product; The filling layer 2 can be made of cushioning materials such as sponge and EPE pearl cotton to provide support and shock absorption functions; The adhesive layer 3 can be made of TPU film, which has good flexibility, weather resistance and compatibility with the inflatable base 4 (such as PVC, TPU film). Through the subsequent high-frequency and high-frequency process, a reliable connection with the inflatable base 4 can be achieved. The adhesive layer 3 is melt-bonded to the surface of the inflatable base 4 through the high-frequency and high-frequency process to form a fixed connection. The manufacturing method of the inflatable product comprises the following steps: Lamination: The breathable layer 1, the filling layer 2, and the adhesive layer 3 are stacked together in sequence, and the multiple layers can be sewn together by needle and thread to form a complete composite layer. The needle and thread pass through the breathable layer 1, the filling layer 2, and the adhesive layer 3. When the multiple layers are sewn together, part of the stitching can be located between the connecting layer and the adhesive layer 3 and adhere to the adhesive layer 3; A connecting layer is provided between the adhesive layer 3 and the inflatable matrix 4 of the composite layer assembly. The adhesive layer 3 and the connecting layer can both be made of TPU film when in use. The connecting layer is respectively attached to the adhesive layer 3 and the inflatable matrix 4. The composite layer is placed under a high-frequency process equipment. The high-frequency vibration of the welding head of the high-frequency process melts and bonds the adhesive layer 3, the connecting layer and the surface layer of the inflatable matrix 4 together. The connecting layer can cover the pinholes caused by sewing, thereby avoiding the reduction of airtightness or the aggravation of local wear caused by the pinholes. When multiple layers are sewn together to form a composite layer through stitching, if the stitching breaks due to long-term wear and tear or local stress concentration, the stitching in the unbroken section will gradually loosen due to tension imbalance, eventually leading to separation of the composite layers, seriously affecting the service life of the product. In this application, when the adhesive layer 3 is melt-bonded to the surface of the inflatable matrix 4 through a high-frequency and high-frequency process, the stitching section adhered to the inner side of the adhesive layer 3 will be fixed to the surface of the inflatable matrix 4 together with the TPU film, forming a physical fixation of the stitching. This design ensures that even if the stitching breaks locally, the stitching on both sides of the break will not easily loosen due to the fixation of the melt-bonded structure of the adhesive layer 3 and the inflatable matrix 4, effectively avoiding the separation of the composite layers due to the overall falling off of the stitching, further improving the structural stability and service life of the product.

[0025] The high-frequency and high-frequency process uses a high-frequency electric field to achieve the melting connection of the material itself. Through this process, the adhesive layer 3 is connected to the inflatable matrix 4. This process does not require additional adhesives, the welding time is short, and it can achieve reliable connection between different materials such as TPU and PVC, TPU and nylon. When the user uses this inflatable product, the cotton breathable layer 1 is in direct contact with the human body. Its natural fiber pores allow air circulation to avoid heat and moisture accumulation. The filling layer 2 can provide cushioning support and improve the touch. Its bottom TPU adhesive layer 3 forms a high-strength connection with the inflatable matrix 4 through a high-frequency and high-frequency process to ensure that the composite layer will not fall off. This design simultaneously solves the environmental protection, breathability and connection strength problems of the existing technology through material combination and process innovation. Example

[0026] When the composite layer is produced by a non-sewing method, the breathable layer 1, the filling layer 2 and the adhesive layer 3 are placed in sequence, and then the multi-layer composite is connected into one by an ultrasonic welding process to form the required composite layer. The prepared composite layer directly adheres the adhesive layer 3 to the surface of the inflatable matrix 4, and then uses high-frequency and high-frequency process equipment to connect and fix the adhesive layer 3 to the surface of the inflatable matrix 4.

[0027] Those skilled in the art will appreciate that the embodiments of the present invention described above and shown in the accompanying drawings are intended only as examples and are not intended to limit the present invention. The objectives of the present invention have been fully and effectively achieved. The functional and structural principles of the present invention have been demonstrated and illustrated in the embodiments. Any variations or modifications may be made to the embodiments of the present invention without departing from the principles described.

Claims

1. An inflatable product, characterized in that: The invention comprises an inflatable matrix (4) and a composite layer with a multi-layer structure arranged on the inflatable matrix (4), wherein the bottom layer of the composite layer is provided with an adhesive layer (3) that is bonded to the inflatable matrix (4), and the adhesive layer (3) of the composite layer is connected to the inflatable matrix (4) through a non-adhesive physical connection process.

2. An inflatable product according to claim 1, characterized in that: The multilayer structure of the composite layer comprises a breathable layer (1), a filling layer (2) and an adhesive layer (3) which are arranged in sequence.

3. An inflatable product according to claim 2, characterized in that: The breathable layer (1), the filling layer (2) and the adhesive layer (3) are stacked to form a composite layer, the layers of the composite layer are connected by sewing, and a connecting layer is provided between the stitched composite layer and the inflatable matrix (4).

4. An inflatable product according to claim 2, characterized in that: The breathable layer (1), the filling layer (2), and the adhesive layer (3) are stacked to form a composite layer, and the breathable layer (1), the filling layer (2), and the adhesive layer (3) are compositely connected by an ultrasonic welding process.

5. The inflatable product according to claim 1, characterized in that: The non-adhesive physical connection process is a high-frequency and high-frequency process, through which the composite layer and the surface layer of the inflatable matrix (4) are melted and bonded together.

6. A method for manufacturing an inflatable product, characterized in that: The following steps are involved: Making a composite layer, stacking the breathable layer (1), the filling layer (2), and the adhesive layer (3) in sequence, and prefabricating the three-layer structure into an independent multi-layer composite layer through a fixing process; Composite fixing: the adhesive layer (3) of the composite layer prepared in step 1 is attached to the surface of the inflatable matrix (4), and a non-adhesive physical connection process is used to melt-bond and fix the adhesive layer (3) and the surface of the inflatable matrix (4).

7. The production method according to claim 6, characterized in that: The fixing process in step 1 is a sewing process, in which the breathable layer (1), the filling layer (2) and the adhesive layer (3) are sewn together into one piece by needle and thread.

8. The manufacturing method according to claim 6, characterized in that: The fixing process in step 1 is to compositely connect the breathable layer (1), the filling layer (2) and the adhesive layer (3) into one piece through an ultrasonic welding process.

9. The manufacturing method according to claim 6, characterized in that: The non-adhesive physical connection process described in step 2 is a high-frequency process.

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