Pad and method for manufacturing a pad

Abstract

To provide a new pad and a method for manufacturing the pad.SOLUTION: A pad according to the present disclosure includes a first layer, a thread-like member, and a second layer. The first layer has a back surface and a front surface opposite the back surface. The thread-like member penetrates the first layer and has a plurality of loop parts and an engaging part. The plurality of loop parts protrudes from the front surface. The engaging part connects the plurality of loop parts and is at least partially disposed on the back surface. The second layer includes a foam material and is bonded to the back surface.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present disclosure relates to a pad and a method for manufacturing the pad.

Background Art

[0002] Conventionally, a pillow pad having protrusions on its surface has been known. The protrusions of such a pad are embedded in a concrete pillow formed on the pad to prevent the pad from falling off the concrete pillow (see, for example, Patent Document 1).

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] Such a pad preferably has protrusions shaped to prevent peeling from the attached member (a concrete pillow in the example of Patent Document 1), and further has a structure in which the protrusions are difficult to peel from the pad. The problem of the present disclosure is to provide a novel pad and a method for manufacturing the pad.

Means for Solving the Problems

[0005] The pad according to the present disclosure includes a first layer, a filamentous member, and a second layer. The first layer has a back surface and a surface opposite to the back surface. The filamentous member penetrates the first layer and has a plurality of loop portions and an engaging portion. The plurality of loop portions protrude from the surface. The engaging portion connects the plurality of loop portions and is at least partially disposed on the back surface. The second layer contains a foaming material and is joined to the back surface.

[0006] A method for manufacturing a pad according to this disclosure comprises the steps of: passing a filamentous member through a first layer to form a plurality of loop portions and engaging portions. The first layer has a back surface and a surface opposite to the back surface. The plurality of loop portions protrude from the surface of the first layer. The engaging portions connect the plurality of loop portions and are located at least partially on the back surface. Furthermore, a method for manufacturing a pad according to this disclosure comprises the steps of: foaming a foamed material to form a second layer; and bonding the first layer, which is integrated with the filamentous member, to the second layer.

[0007] This pad allows for the placement of a loop portion protruding from the surface of the first layer between the mounting member and the pad. This prevents the mounting member and the pad from separating. Furthermore, this pad allows for the placement of an engaging portion exposed on the back surface of the first layer between the back surface of the first layer and the second layer. This prevents the first and second layers from separating. Moreover, this pad manufacturing method allows for the simple and efficient production of a pad with the loop portion and engaging portion formed on the first layer. [Effects of the Invention]

[0008] This disclosure provides a novel pad and a method for manufacturing the pad. [Brief explanation of the drawing]

[0009] [Figure 1] A perspective view of the pad in an embodiment of the present disclosure. [Figure 2] A cross-sectional view of the pad in an embodiment of the present disclosure. [Figure 3] Cross-sectional view of a pad in another embodiment of the present disclosure. [Figure 4] A schematic diagram showing a method for manufacturing a pad in an embodiment of this disclosure. [Modes for carrying out the invention]

[0010] The embodiments of this disclosure will be described below with reference to the drawings. Figure 1 is a schematic perspective view of the pad 1 in the embodiment of this disclosure. In Figure 1, the vertical direction H is defined as the upper side being the top of the paper and the lower side being the bottom, but this does not necessarily coincide with the actual direction of gravity. Figure 2 is a schematic cross-sectional view of the pad 1 in section AA of Figure 1.

[0011] As shown in Figure 1, pad 1 has predetermined lengths in the width direction (an example of a first direction) W, the depth direction (an example of a second direction) D, and the vertical direction H. In this embodiment, pad 1 is formed in a substantially rectangular parallelepiped shape and used as a railway sleeper pad. Specifically, pad 1 and sleeper are bonded together by pouring ready-mix concrete, which will become the sleeper, onto the upper side of pad 1 in the vertical direction H and allowing it to harden. Pad 1, in its integrated state with the sleeper, is placed on the railway track as a vibration damper and sound dampener.

[0012] The pad 1 is not limited to this example; it can be formed in a variety of sizes and shapes to suit its intended use. For example, the pad 1 may be used as a wall material for vibration isolation and sound insulation in residential buildings, or as a damper placed between electric machinery and the floor. In this case, the pad 1 is positioned as a vibration isolation and sound insulation material with the mounting member adhered to its upper side in the vertical direction H.

[0013] As shown in Figure 1, the pad 1 comprises a first layer 2, a plurality of filamentous members 4, a second layer 6, and a third layer 8.

[0014] The first layer 2 has a back surface 21 and a surface surface 22 opposite to the back surface 21. In this embodiment, the first layer 2 is a woven fabric containing a woven material. The first layer 2 is arranged such that the surface surface 22 is on the upper side in the vertical direction H and the back surface 21 is on the lower side in the vertical direction H. Therefore, in this embodiment, the surface surface 22 of the first layer 2 becomes the upper surface of the pad 1.

[0015] As shown in Figure 2, the filamentous member 4 includes a resin thread and penetrates the first layer 2. , Layer 1, 2It is sewn in. In this embodiment, the filamentous member 4 is sewn into the pre-created first layer 2 using an industrial sewing machine or the like. Also, not limited to this, the filamentous member 4 may be woven in simultaneously when the first layer 2 is created. Layer 1, 2 It may be woven in. The filamentous member 4 is continuously sewn from one end to the other end of the first layer 2 along the width direction W. The filamentous member 4 may be sewn into the first layer 2 along the depth direction D, or may be sewn obliquely with respect to the width direction W and the depth direction D.

[0016] A plurality of filamentous members 4 may be arranged at intervals in a direction intersecting the direction in which the filamentous member 4 is sewn into the first layer 2. In this embodiment, the plurality of filamentous members 4 are evenly arranged at regular intervals along the depth direction D.

[0017] The filamentous member 4 has a plurality of loop portions 41 and an engagement portion 42.

[0018] The loop portion 41 protrudes from the surface 22 of the first layer 2. That is, the upper portion 411 of the loop portion 41 is spaced above the surface 22 of the first layer 2 in the vertical direction H. The loop portion has a width 412 and a height 413. In this embodiment, the width 412 of the loop portion 41 is substantially the same as the height 413. Also, the interval 414 between adjacent loop portions 41 of one filamentous member 4 may be determined based on the width 412 and height 413 of the loop portion 41. Not limited to this, the loop portion 41 can be changed to various sizes according to the use and shape of the pad 1. In this embodiment, a plurality of loop portions 41 are formed for one filamentous member 4. That is, for one filamentous member 4, a plurality of loop portions 41 are regularly arranged at intervals 414 in the width direction of the first layer 2.

[0019] With such a configuration, in the process of forming the bolster from fresh concrete, the plurality of loop portions 41 of the pad 1 are fixed in a state of being buried in the fresh concrete. As a result, a layer in which the plurality of loop portions 41 are embedded in the concrete is formed between the pad 1 and the bolster. Therefore, it is possible to prevent the integrally formed pad 1 and the bolster from peeling off.

[0020] In the present embodiment, the loop portion 41 of the pad 1 used as the mat pad is formed such that the width 412 is about 2 mm, the height 413 is about 3 mm, and the interval 414 between adjacent loop portions 41 is about 3 mm.

[0021] The engaging portion 42 connects the plurality of loop portions 41. The engaging portion 42 is at least partially disposed on the back surface 21. In the present embodiment, the engaging portion 42 is disposed between two adjacent loop portions 41 and connects the two adjacent loop portions 41. The engaging portion 42 includes a first portion that continuously penetrates from the end of one loop portion 41 through the front surface 22 to the back surface 21 of the first layer 2, a second portion that is exposed and disposed on the back surface 21, and a third portion that penetrates from the back surface 21 to the front surface 22 and is continuous with the loop portion 41 disposed adjacent to one loop portion 41. A part 421 of the engaging portion 42 has a predetermined length 422 that is exposed and disposed on the back surface 21.

[0022] In the present embodiment, the engaging portion 42 penetrates along the vertical direction H, that is, perpendicularly to the first layer 2. Therefore, the predetermined length 422 of the engaging portion 42 is substantially the same as the interval 414 between adjacent loop portions 41. Not limited to this, the angle at which the engaging portion 42 penetrates the first layer 2 can also be changed to various sizes according to the use and shape of the pad 1. [[ID=!13]] [[ID=!14]]

[0023] [[ID=!15]] A portion 421 of the engaging portion 42 is positioned between the back surface 21 of the first layer 2 and the second layer 6, which will be described later. As a result, the first layer 2 and the second layer 6 are bonded together, with the portion 421 of the engaging portion 42 wrapped around it. Therefore, the portion 421 of the engaging portion 42 can prevent the first layer 2 and the second layer 6 from separating. Furthermore, because the engaging portion 42 is positioned between the first layer 2 and the second layer 6 and bonded together as one, the filamentous member 4 can be prevented from falling off the first layer 2. This prevents the loop portion 41 of the filamentous member 4 from unintentionally falling off and deforming on the surface 22 of the first layer 2.

[0024] A portion 421 of the engaging portion 42 does not protrude from the back surface 21, but is exposed along the back surface 21. The size 422 of the engaging portion 42 that is exposed on the back surface 21 may be determined based on the width 412, height 413, and spacing 414 of the loop portion 41. However, the engaging portion 42 can be changed to various sizes depending on the application and shape of the pad 1.

[0025] In this embodiment, the engaging portion 42 of the pad 1 used as a sleeper pad is formed such that the size 422 exposed on the back surface 21 is approximately 3 mm.

[0026] The loop portion 41 and the engaging portion 42 are arranged alternately and continuously in the first layer 2 from one end to the other in the width direction W, which is the direction in which the thread-like member 4 extends. In other words, in this embodiment, a single thread-like member 4 is sewn into the first layer 2 from one end to the other in the width direction W without interruption, and the loop portion 41 and the engaging portion 42 are arranged alternately in a regular manner.

[0027] The pad 1 may comprise a plurality of filamentous members 4. The plurality of filamentous members 4 may be arranged in parallel or intersecting. In this embodiment, as shown in Figure 1, the plurality of filamentous members 4 are arranged at predetermined intervals 43 in the depth direction D. On the surface 22 of the first layer 2, the loop portions 41 of one filamentous member 4 are regularly arranged at predetermined intervals 414 along the width direction W, and the loop portions 41 of a plurality of filamentous members 4 are regularly arranged at predetermined intervals 43 along the depth direction D. That is, in this embodiment, the loop portions 41 of a plurality of filamentous members 4 are regularly distributed at equal intervals in the width direction W and the depth direction D on the surface 22 of the first layer 2.

[0028] Furthermore, adjacent thread-like members 4 in the depth direction D may be arranged with their respective loop portions 411 centers 415 spaced apart along the width direction W, or they may be arranged to coincide in the width direction W. As shown in Figure 2, in this embodiment, adjacent thread-like members 4 in the depth direction D are arranged with their respective loop portions 411 centers 415 spaced apart along the width direction W. In Figure 2, for clarity, the second thread-like member 4b is shown with a dashed line. In this embodiment, the first thread-like member 4a and the second thread-like member 4b adjacent in the depth direction are arranged with their respective loop portions 41a and 41b centers spaced apart by a length 44 along the width direction W. That is, the second thread-like member 4b is positioned offset from the first thread-like member 4a by a distance of 44 in the width direction W. In this embodiment, the distance 44 between the loop portion 41a of the first filamentous member 4a and the loop portion 41b of the second filamentous member 4b is approximately the same as the size 412 of the loop portion 41. That is, the loop portion 41a of the first filamentous member 4a and the loop portion 41b of the second filamentous member 4b are arranged alternately along the depth direction D. As a result, multiple loop portions 41 are evenly distributed on the surface 22 of the first layer 2 of the pad 1 in the width direction W and the depth direction D.

[0029] The second layer 6 contains a foamed material. In this embodiment, the second layer 6 is a foamed molded member made by foaming polyurethane. The second layer 6 is molded to be thicker in the vertical direction H than the first layer 2 and the third layer 8, which will be described later. In this embodiment, the second layer 6 is formed to be the same size as the first layer 2 in the width direction W and depth direction D. Furthermore, the second layer 6 is formed uniformly in the width direction W and depth direction D with a thickness of approximately 5 mm to 200 mm. However, the thickness of the second layer 6 can be changed to various sizes depending on the application and shape of the pad 1.

[0030] The third layer 8 includes a nonwoven fabric material. In this embodiment, the third layer 8 is a nonwoven fabric. The third layer 8 is formed with the same or greater thickness as the first layer 2 in the vertical direction H. The third layer 8 is not limited to this and may include a metal plate, film, etc. In this embodiment, the third layer 8 is formed to the same size as the first layer 2 and the second layer 6 in the width direction W and depth direction D. The third layer 8 is also formed to a thickness of approximately 5 mm and is uniform in the width direction W and depth direction D. However, the thickness of the third layer 8 can be changed to various sizes depending on the application and shape of the pad 1. The third layer 8 may also be omitted depending on the application and shape of the pad 1.

[0031] Next, we will describe another embodiment of the pad 10 of this disclosure using Figure 3. In this description, we will only explain the differences from the pad 1 of the embodiment shown in Figure 2.

[0032] As shown in Figure 3, in this embodiment, the engaging portion 42 penetrates from the surface 22 to the back surface 21 of the first layer 2, continuously with the loop portion 41, and is exposed to the back surface 21 in multiple stages. In this embodiment, after being exposed to the back surface 21 over a predetermined length 423, the engaging portion 42 folds back inside the first layer 2 and is then exposed to the back surface 21 again over a predetermined length 423. That is, in the embodiment of Figure 2, the engaging portion 42 is exposed to the back surface 21 once over a length 422 for each loop portion 41, whereas in this embodiment, the engaging portion 42 is exposed to the back surface 21 twice over a length 423 for each loop portion 41. In this embodiment, the engaging portion 42 is formed so that its length 423 is approximately 1.5 mm. As a result, the engaging portion 42 is positioned between the back surface 21 of the first layer 2 and the second layer 6, preventing the first layer 2 and the second layer from separating.

[0033] In addition, the length 423 of the engagement portion 42 exposed on the back surface 21 of the first layer 2 can be changed to various sizes depending on the application and shape of the pad 1. Furthermore, the number of times the pad 1 folds inside the first layer 2, that is, the number of times the engagement portion 42 is exposed on the back surface 21 relative to the loop portion 41 of the pad 1, can also be changed to various sizes.

[0034] Next, a method for manufacturing the pad 1 in an embodiment of the present disclosure will be described using Figure 4. As shown in Figure 4, the method for manufacturing the pad 1 of the present disclosure M comprises a loop forming step M1, a foam molding step M2, an adhesive step M3, a cutting step M4, and a stacking step M5.

[0035] In the loop formation step M1, a woven fabric member to be the first layer 2 is prepared, and the thread-like member 4 is passed through the first layer 2 to form a loop portion 41 and an engaging portion 42. In this embodiment, the first layer 2 and thread-like member 4 are formed by regularly sewing resin threads into a woven fabric member that has been formed to a predetermined size in the width direction W and depth direction D using a sewing machine. However, the first layer 2 and thread-like member 4 may also be formed by sewing resin threads into the woven fabric member and then cutting it to a predetermined size.

[0036] Next, in the foam molding process M2, the foam material is foamed to form the second layer 6. In this embodiment, the second layer 6 is formed by a molding method in which the foam material is poured into a mold formed to a predetermined shape, and the material is foamed and heated inside the mold.

[0037] Next, in bonding step M3, the first layer 2 and thread-like member 4 formed in loop portion formation step M1 are bonded to the second layer 6 formed in foam molding step M2. That is, in bonding step M3, the back surface 21 of the first layer 2, which is integrated with the thread-like member 4, is bonded to the second layer 6. In this embodiment, the first layer 2 and thread-like member 4 are bonded to the pre-formed second layer 6 to form a single unit. Furthermore, a third layer 8, which is a nonwoven fabric, may be bonded to the second layer 6.

[0038] The method is not limited to this; for example, the second layer 6 may be formed by a conveyor method in which foaming and heating are performed on a conveyor moving at a predetermined speed, and the second layer 6, the first layer 2, and the filamentous member 4 may be bonded together by arranging the first layer 2 and the filamentous member 4, which are integrated with the foamed material in the process of solidification. In this case, the foaming process M2 and the bonding process M3 can be completed simultaneously by arranging the first layer 2 with the back surface 21 of the first layer 2, where the engaging portion 42 of the filamentous member 4 is exposed, to the foamed material in the process of solidification.

[0039] In this embodiment, the foam molding process M2 and the bonding process M3 were carried out in steps, but the disclosure is not limited thereto. That is, when forming the second layer 6 by the molding method, the foam molding process M2 and the bonding process M3 may be carried out simultaneously. Also, when forming the second layer 6 by the conveyor method, the foam molding process M2 and the bonding process M3 may be carried out in steps. In addition, various methods can be used to carry out the foam molding process M2 and the bonding process M3 depending on the application and shape of the pad 1.

[0040] Next, in cutting step M4, the integrated first layer 2, thread-like member 4, second layer 6, and third layer 8 are cut to a predetermined size to form the pad 1. In this embodiment, the first layer 2, thread-like member 4, second layer 6, and third layer 8 are cut after they have been integrated, but the invention is not limited to this, and the first layer 2 and thread-like member 4, which have been formed to a predetermined size in advance, may be bonded to the second layer 6, which has been formed or cut to a predetermined size.

[0041] Finally, in the loading process M5, at least two pads 1 are placed on top of each other with their loop portions 41 facing each other. That is, in this embodiment, the two pads 1 are loaded on top of each other in the vertical direction H so that their surfaces 22 face each other. As a result, the tip of the loop portion 41 of one pad 1 is in contact with the surface 22 of the first layer 2 of the other pad 1. At this time, the pads 1 may be stacked offset in the width direction W and depth direction D so that the tips of their loop portions 41 do not come into contact with each other. As a result, the two pads 1 stacked in the vertical direction H have their loop portions 41 interfere with each other, restricting movement in the width direction W and depth direction D. As a result, it is possible to prevent the two pads 1 from moving or shifting during transport.

[0042] In this disclosure, at least two pads 1 are stacked in the vertical direction H, but the invention is not limited to this, and the two pads 1 may also be stacked in the width direction W and the depth direction D.

[0043] As described above, this disclosure provides a novel pad and a method for manufacturing the pad. [Explanation of symbols]

[0044] 1(10): Pad 2: First layer 21: Back side 22: Front side 4: Thread-like member 41 (41a, 41b): Loop portion 42: Engaging portion 6:Second layer W: Width direction (first direction) D: Depth direction (second direction) M: Manufacturing method M1: Loop Forming Process M2: Bubble Forming Process M3: Adhesion Process M4: Cutting Process

Claims

1. A first layer having a back surface and a surface opposite to the said back surface, A thread-like member that penetrates the first layer, having a plurality of loop portions protruding from the surface, and at least one engaging portion connecting the plurality of loop portions and at least partially located on the back surface, A second layer containing foam material and bonded to the back surface, Equipped with, pad.

2. The thread-like member includes a resin thread, and the loop portion and the engaging portion are arranged alternately and continuously. The pad according to claim 1.

3. The filamentous members comprise a plurality of the aforementioned thread-like members, The thread-like members are arranged in a second direction that intersects the first direction in which the engaging portion and the loop portion are arranged side by side. The pad according to claim 1 or 2.

4. In the second direction, adjacent thread-like members are arranged such that, when viewed from the second direction, the centers of their respective loop portions are spaced apart along the first direction. The pad according to claim 3.

5. The thread-like member is continuous from one end to the other of the first layer in the first direction in which the engaging portion and the loop portion are arranged side by side. The pad according to any one of claims 1 to 4.

6. The process involves passing a filamentous member through a first layer having a back surface and a surface opposite to the back surface, thereby forming a plurality of loop portions protruding from the surface of the first layer, and engaging portions connecting the plurality of loop portions and at least partially positioned on the back surface. A process of foaming the foam material to form a second layer, A step of bonding the back surface of the first layer, which is integrated with the filamentous member, to the second layer, Equipped with, A method for manufacturing a pad according to claim 1.

7. The process of arranging at least two pads, each comprising the filamentous member, the first layer, and the second layer, with their loop portions facing each other and overlapping; Furthermore, A method for manufacturing a pad according to claim 6.

8. The first layer has a first through hole and a second through hole different from the first through hole, The loop portion is connected to the first engaging portion in the first through hole and the second engaging portion in the second through hole. A pad according to any one of claims 1 to 5.

9. The at least one engaging portion comprises a first portion connected to one of the loop portions and exposed on the back surface, and a second portion connected to the other loop portion and exposed on the back surface, Includes an intermediate portion connected between the first portion and the second portion and located within the first layer. A pad according to any one of claims 1 to 5.

10. A vibration-damping material comprising a pad according to any one of claims 1 to 5 and 8 to 9.

11. A soundproofing material comprising a pad according to any one of claims 1 to 5 and 8 to 9.

12. A sleeper pad comprising the pad according to any one of claims 1 to 5 and 8 to 9.

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