Three-dimensional cushioning material and method for manufacturing the same

Abstract

This invention relates to a method for manufacturing a three-dimensional cushioning material, and provides a three-dimensional cushioning material and a method for manufacturing the same. The three-dimensional cushioning material consists of a base layer 10 and a composite mesh material 20. The base layer 10 provides the necessary mechanical support for the entire three-dimensional cushioning material. The composite mesh material 20 is designed to have a porous structure, forming effective air convection and diffusion, and preventing the absorption of moisture and heat and the generation of odors due to long-term contact between the cushioning material and the human body. The structural design of the composite mesh material 20 combines multiple mesh materials, and by overlapping mesh materials with different pore sizes in each layer, protrusions 11 are formed on the base layer 10 under the action of an external molding force, and by pushing out the mesh holes, protruding contact points are formed on the mattress material, which buffers the force on the contact surface and creates a pressing effect at the contact points. Furthermore, by optimizing the structural design of the protrusions 11, a cavity structure can be formed, completing the airflow from the composite mesh material 20 to the base layer 10, and realizing the functions of breathability and moisture removal.

Description

Technical Field

[0001] The present invention relates to the field of manufacturing cushion materials, and particularly to three-dimensional cushion materials and their manufacturing methods.

Background Art

[0002] Cushion materials are an indispensable part of daily life. For example, when doing exercises such as yoga, a yoga mat is used to prevent the human body from directly touching the floor surface. Also, when sitting on a chair, a cushion or a backrest is used to avoid direct contact with the seat surface or the backrest. Furthermore, when lying down on a bed, a mattress has been used to prevent the human body from directly touching the bed frame.

[0003] However, since the cushion materials currently commonly used need to provide sufficient mechanical support, many of them do not have air permeability or have insufficient air permeability. Therefore, when in contact with the human body for a long time, the hot air and moisture emitted from the human body tend to be trapped inside and are difficult to discharge. There is a risk of generating unpleasant odors and breeding bacteria due to long-term use.

Summary of the Invention

Problems to be Solved by the Invention

[0004] Therefore, the present invention focuses on the above technical problems and provides a three-dimensional cushion material that combines practicality and air permeability.

Means for Solving the Problems

[0005] The present invention discloses a three-dimensional cushion material. The three-dimensional cushion material includes at least one base material layer, a composite mesh material is provided on the upper surface of the base material layer, and a plurality of protrusions are formed on the base material layer.

[0006] Preferably, the composite mesh material consists of at least two types of mesh-like bodies laminated together, thereby forming at least one stepped portion between the bottom and top surfaces of each projection, and each mesh-like body has multiple meshes arranged in a matrix.

[0007] The composite mesh material comprises at least a first mesh-like structure positioned close to the base material layer and a second mesh-like structure positioned away from the base material layer, wherein the pore diameter of the mesh of the first mesh-like structure is larger than the pore diameter of the mesh of the second mesh-like structure.

[0008] The height of the multiple protrusions gradually increases or decreases along the first direction.

[0009] Preferably, a notch is formed on the top surface of the projection.

[0010] The aforementioned base material layer is a single-layer or multi-layer structure made of an elastic material and / or diatomaceous earth.

[0011] Preferably, an internal space is formed between the bottom surface and the top surface of the projection.

[0012] The present invention further discloses a method for manufacturing a three-dimensional cushioning material. The manufacturing method is for manufacturing the three-dimensional cushioning material and includes the following steps. S1: A process of heating the substrate layer to a temperature of 150-200°C to soften it. S2: A process in which a composite mesh material having multiple meshes arranged in a matrix is ​​placed on the upper surface of the base layer, a molding force is applied to the base layer and / or each mesh material to deform the base layer, and multiple protrusions arranged in a matrix are formed in the mesh of the outermost layer of the composite mesh material.

[0013] Preferably, the process further includes the following steps. S3: Step of cutting off the top surface of the projection to form a notch.

[0014] The molding force in step S2 is formed by a combination of one or more of the following: gas pressure, vacuum suction force, pressure due to temperature difference, use of a pressure sheet, filling with a high-density material, or filling with a foamed material. [Effects of the Invention]

[0015] By employing the above-described technical means, the present invention has the following advantageous effects.

[0016] The three-dimensional cushioning material designed in this invention is composed of a base layer and a composite mesh material, with the base layer providing the necessary mechanical support function for the entire cushioning material. On the other hand, the composite mesh material has a porous structure, which forms effective air convection and diffusion, thereby suppressing moisture absorption and heat absorption when the cushioning material is in contact with the human body for a long period of time, and preventing the generation of unpleasant odors.

[0017] By designing the structure of the composite mesh material, multiple layers of mesh material are combined and overlapped with different pore sizes in each layer. Under the action of external molding forces, the base layer deforms, and protrusions are formed as if pushed out from the mesh, creating protruding contact points in the cushioning material. This buffers the magnitude of the force acting on the contact surface and provides a contact effect accompanied by a feeling of pressure from the contact points. Furthermore, by optimizing the structural design of the protrusions, a cavity structure can be formed, creating air passages that penetrate from the composite mesh material to the base layer, resulting in excellent breathability and moisture drainage.

[0018] To enable a clearer understanding of the present invention, the present invention will be described in more detail below with reference to specific embodiments and drawings. [Brief explanation of the drawing]

[0019] [Figure 1] This is a three-dimensional exploded view showing the structure of the three-dimensional cushioning material of the present invention. [Figure 2] This is a schematic diagram showing a first embodiment of the three-dimensional cushioning material of the present invention. [Figure 3]It is a cross-sectional view of the protrusion in the three-dimensional cushioning material of the present invention (along the line 3-3' of FIG. 2). [Figure 4] It is a schematic diagram showing a second embodiment of the three-dimensional cushioning material of the present invention. [Figure 5] It is a cross-sectional view of the protrusion according to a third embodiment of the three-dimensional cushioning material of the present invention. [Figure 6] It is a process flow diagram showing a manufacturing method of the three-dimensional cushioning material of the present invention.

Embodiments for Carrying out the Invention

[0020] In order to more clearly understand the object, technical means, and advantages of the present invention, the present invention will be described in more detail below with reference to the accompanying drawings and specific embodiments. However, the specific embodiments shown here are for explaining the present invention only and do not limit the present invention.

[0021] (First Embodiment) As shown in FIGS. 1 and 2, this embodiment discloses a three-dimensional cushioning material. The three-dimensional cushioning material includes a base material layer 10, a composite mesh material 20 is provided on the upper surface of the base material layer 10, and a plurality of protrusions 11 are formed on the base material layer 10.

[0022] The composite mesh material 20 is composed of a first mesh body 21 disposed close to the base material layer 10 and a second mesh body 22 disposed away from the base material layer 10, and the pore diameter of the mesh of the first mesh body 21 is larger than the pore diameter of the mesh of the second mesh body 22.

[0023] The base material layer 10 is a single-layer or multi-layer structure made of an elastic body or diatomaceous earth, and may be composed of a single layer of elastic body and a single layer of diatomaceous earth, or a multi-layer elastic body and a multi-layer diatomaceous earth, or a combination of a multi-layer elastic body and a multi-layer diatomaceous earth. The elastic body may be a thermoplastic elastic body or a thermosetting elastic body. The composite mesh material 20 is made of a stable material, and may be, for example, a metal mesh or a fiber mesh. In other embodiments, it is also possible to select other rigid materials as the composite mesh material 20.

[0024] As shown in Figure 3, in the first embodiment of the present invention, each projection 11 has at least one stepped portion 11c between its bottom surface 11b and top surface 11a, so that the contour of the projection 11 is trapezoidal. When the projection 11 comes into contact with the human body, it exerts a massage effect and an acupressure effect.

[0025] In other embodiments, the composite mesh material 20 may be constructed by laminating three or more mesh-like structures, thereby forming two or more stepped portions 11c between the bottom surface 11b and the top surface 11a of the projection 11. Furthermore, there is an internal space between the bottom surface 11b and the top surface 11a of the projection 11. In this embodiment, the projection height h of each projection 11 is equal (the projection height h is defined as the distance between the bottom surface 11b and the top surface 11a of the projection 11).

[0026] Similarly, when the base layer 10 is laid with its bottom surface on a floor or the surface of another article, the internal space of the protrusion 11 functions as an air-retaining space, and the protrusion 11 exhibits an airbag-like cushioning effect.

[0027] (Second embodiment) As shown in Figure 4, this embodiment is based on the structure of the first embodiment, with further optimization of the structural design of the protrusion, and proposes the following configuration: A portion of all the protrusions 11 is selected, and a notch 13 is formed on the top surface 11a of the protrusion 11. This notch 13 functions as an air vent, improving the breathability of the three-dimensional cushioning material and preventing the growth of bacteria due to moisture and dampness. In addition, the air chamber formed within the cushioning material by the three-dimensional structure of the protrusions 11 also has the function of preventing liquid that has flowed into the cushioning material from overflowing upwards.

[0028] (Third embodiment) As shown in Figure 5, this embodiment is based on the structures of the first and second embodiments, with further optimization of the structural design of the protrusions for different usage scenarios, and proposes the following configuration: The three-dimensional cushioning material can be used as a seat cushion, mattress, insole, floor mat, yoga mat, play mat, or foot pad, and the strength of the molding force applied to the composite mesh material 20 can be adjusted according to the user's needs. The heights h1, h2, h3, h4, h5, h6 of each of the multiple protrusions 11 arranged in each row gradually decrease along the first direction X (the protrusion heights h1, h2, h3, h4, h5, h6 are defined as the distance between the bottom surface 11b and the top surface 11a of the protrusion 11), thereby accommodating a wider range of applications. Similarly, in other embodiments, the heights h1, h2, h3, h4, h5, h6 of each of the multiple protrusions 11 arranged in each row may gradually increase along the first direction X, or vary along other directions.

[0029] Furthermore, the three-dimensional cushioning material can be equipped with light-emitting elements or electronic components, which are vibrating or acoustic components, thereby enhancing the practicality of the three-dimensional cushioning material. In addition, a waterproof layer can be applied to the surface of the three-dimensional cushioning material to suppress the intrusion of moisture and humidity into the interior of the cushioning material and to provide a waterproofing effect.

[0030] (Fourth embodiment) As shown in Figure 6, the present invention further discloses a method for manufacturing a three-dimensional cushioning material, which includes the following steps. S1: A step of heating the base layer 10 at a temperature of 150-200°C to soften it. S2: A step of placing a composite mesh material 20 having a plurality of meshes 21a, 22a arranged in a matrix on the upper surface of the base layer 10, and applying a molding force to the base layer 10 and / or the composite mesh material 20 to deform the base layer 10 toward the composite mesh material 20, thereby forming a plurality of protrusions 11 arranged in a matrix on the base layer 10, and S3: A step of cutting off at least a portion of the top surface 11a of the projection 11 to form a notch 13.

[0031] The molding force is formed by a combination of one or more of the following: gas pressure, vacuum suction force, pressure due to temperature difference, use of a pressure sheet, filling with high-density material, and filling with foamed material.

[0032] Furthermore, the composite mesh material 20 is separable and can be removed after the protrusions 11 are formed, thus preventing injury to the human body from contact with the hard material. Alternatively, the composite mesh material 20 may be integrated with the base layer 10, and the base layer 10 covers the composite mesh material 20, making it impossible to remove the composite mesh material 20. In this way, the base layer 10 and the composite mesh material 20 are bonded together, so there is no risk of injury even if the human body comes into contact with it.

[0033] The specific embodiments described above further illustrate the object, technical means, and advantageous effects of the present invention, but these are merely specific embodiments of the present invention and do not limit it. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention are all covered by the protection of the present invention. [Explanation of symbols]

[0034] 10 Base material layer 11 Protrusion 11a Top surface 11b Bottom 11c Step section 13 cuts 20 Composite Mesh Material 21 First reticular structure 21a Mesh 22 Second Reticular Structure 22a Mesh d1, d2 pore diameter h, h1~h6 Protrusion height X First direction

Claims

1. It is a three-dimensional cushioning material, The material comprises at least one base layer, a composite mesh material is provided on the upper surface of the base layer, and a plurality of protrusions are formed on the base layer. A three-dimensional cushioning material characterized by the following features.

2. The composite mesh material consists of at least two types of mesh-like structures stacked together, thereby forming at least one stepped portion between the bottom and top surfaces of each of the protrusions, and each of the mesh-like structures has multiple meshes arranged in a matrix. The three-dimensional cushioning material according to claim 1.

3. The composite mesh material is composed of at least a first mesh structure positioned close to the base layer and a second mesh structure positioned away from the base layer, wherein the pore size of the mesh of the first mesh structure is larger than the pore size of the mesh of the second mesh structure. The three-dimensional cushioning material according to claim 2.

4. The height of the multiple protrusions gradually increases or decreases along the first direction. The three-dimensional cushioning material according to claim 1.

5. A notch is formed on the top surface of the aforementioned projection. The three-dimensional cushioning material according to claim 1.

6. The aforementioned base material layer has a single-layer or multi-layer structure made of an elastic material and / or diatomaceous earth. The three-dimensional cushioning material according to claim 1.

7. An internal space is formed between the bottom surface and the top surface of the aforementioned projection. A three-dimensional cushioning material according to any one of claims 1 to 6.

8. A method for manufacturing a three-dimensional cushioning material, Used to manufacture a three-dimensional cushioning material according to any one of claims 1 to 6, S1: A step of heating the base material layer to a temperature of 150-200°C to soften it, and, S2: A process in which a composite mesh material having multiple meshes arranged in a matrix is ​​placed on the upper surface of the base material layer, a molding force is applied to the base material layer and / or each mesh material to deform the base material layer, and multiple protrusions arranged in a matrix are formed in the mesh of the outermost layer of the composite mesh material. including A method for manufacturing a three-dimensional cushioning material characterized by the following:

9. S3: Further includes the step of cutting off the top surface of the projection to form a notch. A method for manufacturing a three-dimensional cushioning material according to claim 8.

10. The molding force in step S2 is formed by a combination of one or more of the following: gas pressure, vacuum suction force, pressure due to temperature difference, use of a pressure sheet, filling with a high-density material, or filling with a foamed material. A method for manufacturing a three-dimensional cushioning material according to claim 8.

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