Spinned air mattresses and their manufacturing methods.

Abstract

The present invention relates to a type of drawn-fiber air mattress and its method of manufacture. This method includes: initially fixing the first and second face layers, cut with reinforcing straps, then trimming and shaping these face layers; next, welding the first and second face layers to the two corresponding sides of the drawn-fiber body, and trimming the face layers again. Next, clamping the two ends of the side wall, where the air nozzle is attached, and then pumping air between the first face layer and reinforcing straps, as well as between the second face layer and reinforcing straps, performing sequential welding and bonding from top to bottom. Finally, trimming the remaining edges and checking for airtightness to ensure stability during use.

Description

Drawing air mattress and manufacturing method thereof

[0001] Declaration of priority

[0002] This application claims the benefit of priority to Chinese Patent Application No. 202311452076.3, filed on November 2, 2023, entitled “A Method for Manufacturing a Brushed Inflatable Mattress,” and Chinese Patent Application No. 202322966762.4, filed on November 2, 2023, entitled “A Method for Manufacturing a Brushed Inflatable Mattress,” and the entire contents of the above applications are incorporated herein by reference. Technical Field

[0003] The embodiments of the present application relate to the technical field of mattresses, and in particular to a drawn air mattress and a manufacturing method thereof. Background Art

[0004] As people's quality of life gradually improves, camping has become a fashionable leisure activity. As stable, lightweight, and easily stored mattresses, air mattresses are widely used in outdoor camping and other situations where storage is crucial. Inflatable mattresses not only provide sufficient support but also allow them to be stored in a bag when not in use, improving space utilization. This high space utilization makes them suitable for more than just outdoor camping. Traditional air mattresses on the market typically consist of upper and lower sheets, welded together to form a chamber. Inflatable holes are provided in the side panels to allow air to flow in, providing sufficient support.

[0005] However, in the inflatable mattress shown in FIG1 , due to certain limitations of traditional processing, the four sides of the mattress bulge outward and the cross-section is elliptical. In order to improve the aesthetics, a cavity 6 connected to the inner cavity of the mattress is usually retained at the connection between the side 3 and the surface layer 2 after processing, so that the inflatable mattress can be normally stored. However, due to the presence of the cavity 6 at the connection, the support of the inflatable mattress on its peripheral sides is relatively low when in use, resulting in the user falling due to the low support when the user approaches the peripheral sides of the mattress during use, affecting the user experience. Summary of the Invention

[0006] The purpose of this utility model is to address the above-mentioned problems in the existing technology and propose a drawing air mattress and a manufacturing method thereof. The technical problem to be solved by this application is: how to improve the user experience of users.

[0007] To solve the above problems, on the first aspect, an embodiment of the present application provides a brushed inflatable mattress, comprising a brushed body and two surface layers and side panels wrapped around the brushed body, both ends of the two surface layers being welded to the side panels, and characterized in that the outer edges of the two surface layers are welded to connecting belts that overlap with the side panels, the connecting belts comprising a bonding belt and a reinforcing belt, the side panels partially overlap with the bonding belt, and the reinforcing belt covers the above-mentioned overlapping position, so that the ends of the side panels can be clamped and connected between the bonding belt and the reinforcing belt.

[0008] In a second aspect, an embodiment of the present application further provides a method for manufacturing a wire drawing air mattress, wherein the mattress comprises a wire drawing body formed by cutting, a first surface layer, a second surface layer, and side panels, wherein the side panels are provided with an air pump and an air nozzle, and the ends of the side panels are connected to the first surface layer or the second surface layer via a reinforcing strip and the outer side surface of the first surface layer or the second surface layer. The manufacturing method comprises the following steps:

[0009] S1. Weld the outer edges of the first surface layer and the second surface layer to the reinforcing strips respectively, and trim them to control the corresponding dimensions of the reinforcing strips;

[0010] S2. Welding the first surface layer and the second surface layer to the wire drawing body to form a mattress body, and cutting the first surface layer and the second surface layer to control the size;

[0011] S3. Weld one side of the cut first surface layer to the outer side of the upper end of the side panel through a reinforcing strip, and directly weld the other side to the inner side of the upper end of the side panel;

[0012] S4. Weld the outer side of the lower end of the side panel to the reinforcing strip located on the second surface layer, and directly weld the inner side of the lower end of the side panel to the second surface layer. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are merely embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on the provided drawings without any creative work.

[0014] FIG1 is a half-cutaway perspective view of a mattress in the prior art;

[0015] FIG2 is a schematic diagram of the exploded structure of a wire drawing air mattress provided by an embodiment of the present invention;

[0016] FIG3 is a schematic cross-sectional view of a wire drawing air mattress provided in an embodiment of the present invention;

[0017] FIG4 is a flow chart of a method for manufacturing a wire drawing air mattress according to an embodiment of the present invention;

[0018] FIG5 is a flow chart of a method for manufacturing a wire drawing air mattress according to an embodiment of the present invention.

[0019] FIG6 is a schematic perspective cross-sectional view of the drawing air mattress according to an embodiment of the present invention.

[0020] In the figure: 1. wire drawing body; 2. surface layer; 21. first surface layer; 22. second surface layer; 3. side panel; 3a. air hole; 3a1. air nozzle; 3a2. pull ring; 4. connecting belt; 4a. bonding belt; 4b. reinforcement belt; 4c. inner indentation; 4d. outer indentation; 5. air pump; 5b. air pump hole; 6. chamber. DETAILED DESCRIPTION

[0021] To make the objectives, technical solutions, and advantages of the present disclosure more clear, the present disclosure will be further described in detail below with reference to the accompanying drawings. It is apparent that the embodiments described are only a portion of the embodiments of the present disclosure, rather than all of them. All other embodiments derived by persons of ordinary skill in the art based on the embodiments of the present disclosure without creative effort are intended to fall within the scope of protection of the present disclosure.

[0022] The present application provides a wire-drawn inflatable mattress, as shown in FIG2 . A wire-drawn body 1 is covered with a surface layer 2 on top and bottom. A connecting belt 4 comprising a laminating belt 4a and a reinforcing belt 4b is disposed along the outer edge of the surface layer 2. The laminating belt 4a is positioned below the surface layer 2, while the reinforcing belt 4b is positioned above the laminating belt 4a. Side panels 3 are also disposed around the periphery of the wire-drawn body 1. The ends of the side panels 3 overlap and are welded to the laminating belt 4a. The reinforcing belt 4b is positioned where the laminating belt 4a and the side panels 3 overlap. Alternatively, the laminating belt 4a may be positioned above the surface layer 2. Alternatively, the laminating belt 4a may be formed as part of the surface layer 2.

[0023] As shown in Figure 3, the side panels 3 of the brushed air mattress are equipped with air nozzles 3a1 and air holes 3a. A removable air pump 5 is installed inside the brushed air mattress. Both ends of the side panels 3 are connected to the upper and lower surface layers 2 of the brushed body 1 via adhesive tape 4a and reinforcing tape 4b. One end of the adhesive tape 4a is welded to the surface layer 2, forming an inner indentation 4c. The other end overlaps and is adhesively bonded to one end of the side panel 3. The reinforcing tape 4b covers the overlapping portion of the side panel 3 and the adhesive tape 4a, sandwiching the ends of the side panel 3 between the adhesive tape 4a and the reinforcing tape 4b. The reinforcing tape 4b is welded to the adhesive tape 4a at one end, forming an outer indentation 4d. The reinforcing tape 4b is formed by welding the adhesive tape 4a to the PVC material and the PVC adhesive fabric.

[0024] In summary, the main working principle of the present application is: by coordinating the air pump 5 in the drawn inflatable mattress with the air nozzle 3a1 on the side panel 3, and inputting air into the drawn inflatable mattress, the support of the air cushion is improved by increasing its internal air pressure, and during the inflation process, the distance between the two surface layers 2 continues to increase, and because the two surface layers 2 are connected by the connecting belt 4 and the side panel 3, wherein the inner side wall of one end of the side panel 3 is connected to the bonding belt 4a, and one end of the bonding belt 4a is welded to the surface layer 2 by high-frequency welding equipment and forms an inner indentation 4c. Therefore, the two ends of the side panel 3 are stretched to both sides by the influence of the surface layer 2, so that the inner wall of the side panel 3 gradually approaches the side wall of the drawn body 1, and in order to enhance the connection strength between the side panel 3 and the bonding belt 4a, a reinforcing belt 4b is covered on the overlapping part of the side panel 3 and the bonding belt 4a. The reinforcing band 4b is welded to the bonding band 4a to form an external indentation 4d, and the side panel 3 is connected to the surface layer 2 by clamping the bonding band 4a and the reinforcing band 4b, thereby ensuring that the side panel 3 is tightly connected and does not leak. At the same time, the side panel 3 is stretched toward both ends during inflation and gradually approaches the drawing body 1, avoiding the middle position of the side panel 3 from bulging outward, thereby improving the aesthetics. Compared with the elliptical bulges on all sides in Figure 1, and chambers 6 are provided above and below the bulges, the process of this embodiment is simpler, and under the same area, the support coverage area is larger, which can avoid tipping due to insufficient side support, thereby improving user experience. In the storage process after use, due to the simple structure, the side panel 3 only bulges outward and folds, so that the thickness of the edge is lower during the folding process, which is convenient for users to fold and store.

[0025] In addition, the surface layer 2 is welded to the bonding tape 4a to form an internal indentation 4c, thereby ensuring the strength of the welded connection and avoiding air leakage or falling off due to welding defects caused by the presence of foreign matter on the surface. The reinforcing tape 4b is welded to the bonding tape 4a by high-frequency welding equipment to form an external indentation 4d. By welding the bonding tape 4a and the reinforcing tape 4b to the surface layer 2 in turn, insufficient welding caused by overlapping the reinforcing tape 4b and the bonding tape 4a is avoided, thereby improving the stability of the welding.

[0026] Compared with the prior art, the wire drawing air mattress provided by this application has the following advantages:

[0027] 1. This solution mainly includes a drawing body, a surface layer wrapped around the drawing body, and side panels. The surface layer and the side panels are connected by a connecting belt composed of a bonding belt and a reinforcing belt. After inflation, the two ends of the side panels are subjected to an outward stretching force, thereby preventing the mattress from bulging outward. While improving the aesthetics, the support of the inflatable mattress is more comprehensive, thereby enhancing the user experience.

[0028] 2. In this solution, the air pump is built into the air mattress and an air nozzle with air holes is provided on the side, thereby improving the portability of the air mattress.

[0029] The present application also provides a method for manufacturing a drawn air mattress, which can be used to manufacture the drawn air mattress provided in the above embodiment.

[0030] Referring to Figures 4 to 6 , this brushed mattress includes a first surface layer 21, a second surface layer 22, and a brushed body 1 connected to the support surfaces of the first and second surface layers 21, 22. The first and second surface layers 21, 22 are further connected by side panels 3 located on the sides of the brushed body 1. Reinforcement strips 4b are provided at both ends of the side panels 3. One end of the reinforcement strip 4b is welded to the surface layer 2 via a high-frequency device, forming an external indentation 4d, while the other end is welded to the outer sides of the two ends of the side panels 3. An air nozzle 3a1 and an air pump 5 are installed in the middle of the side panels 3. The first and second surface layers 21, 22, and brushed body 1 are welded to form an internal indentation 8.

[0031] As shown in FIG6 , after the drawing and cutting of the drawing body 1 , the first surface layer 21 , the second surface layer 22 and the reinforcing strip 4 b are completed, the main processing steps of the drawing mattress are as follows:

[0032] S1. Weld the outer edges of the first surface layer 21 and the second surface layer 22 to the reinforcing strip 4b, trim the reinforcing strip 4b to control its size, and then place it on a workbench to check for pressure leaks or folds. Place unqualified products in an unqualified product area, and then further process qualified products.

[0033] S2. Remove the welded first surface layer 21 and second surface layer 22 from the workbench, lay them flat, and then weld the first surface layer 21, second surface layer 22 to the wire drawing body 1 using a high-frequency welding device. Form inner indentations 8 on both the first surface layer 21 and the second surface layer 22 to form the mattress body. Then, place the mattress on the workbench, cut the first surface layer 21 and the second surface layer 22 to control their sizes, and prepare for the next step.

[0034] S3. Remove the mattress body from the workbench and weld one side of the cut first surface layer 21 to the outer side of the upper end of the side panel 3 via the reinforcing strip 4b, and the other side directly to the inner side of the upper end of the side panel 3;

[0035] S4. Weld the outer side of the lower end of the side panel 3 to the reinforcing strip 4b located on the second surface layer 22, and directly weld the inner side of the lower end of the side panel 3 to the second surface layer 22. After welding, place the finished product on a workbench.

[0036] S5. Place the finished product on the workbench and check whether there are any appearance defects. If there are any appearance defects, place them in the unqualified product area. After the qualified products are cut off, samples are taken for inspection and packaged after inspection.

[0037] Before welding the side panels 3 to the mattress body, lines are drawn on the pre-cut side panels 3. Holes for the air nozzles 3a1 and the air pump 5 are created according to the lines. The dimensions of the overlapping portions of the reinforcing strip 4b, the first surface layer 21, and the second surface layer 22 are also determined. This facilitates the subsequent welding of the first and second surface layers 21, 22, and the reinforcing strip 4b. After the holes are opened, the air nozzles 3a1 are pressed into the side panels 3 using a machine, with the side with the pull ring 3a2 positioned outside the side panels 3. The panels are then placed on a workbench, with the pull ring 3a2 facing outward, one by one. Finally, the air pump 5 is pressed into the air pump hole 5b in the side panels 3 using a mold.

[0038] The mattress body and side panels 3 of the brushed mattress are first welded to the inner side of the reinforcing band 4b on the first surface layer 21, then to the outer side of the first surface layer 21, then to the outer side of the second surface layer 22, and finally to the inner side of the reinforcing band 4b on the second surface layer 22. The side panels 3 are welded to the mattress body from top to bottom along the height direction of the brushed mattress using high-frequency welding equipment, facilitating processing and improving production efficiency. Furthermore, by first welding the reinforcing band 4b and then welding it to the brushed body 1, after the reinforcing band 4b is welded, it is convenient to better position the first surface layer 21 and the second surface layer 22 when they are fixed to the brushed body 1, reducing the risk of defective products due to misalignment. This ensures that the brushed mattress has sufficient support while improving production efficiency.

[0039] Compared with the prior art, the manufacturing method of the drawn air mattress provided by this application has the following advantages:

[0040] 1. This solution directly connects the side panels by welding the surface layer and the reinforcing belt, so that the side panels are gradually stretched during the inflation process of the inflatable mattress, so that they fit as closely as possible to the side of the wire drawing body, thereby increasing the support surface and ensuring that the mattress is evenly stressed. At the same time, the two ends of the side panels are welded to the wire drawing body from top to bottom, and the fabric is cut after welding to avoid the fabric being too long and affecting its use and aesthetics. While directly connecting the side panels to the surface layer and improving the connection strength through the reinforcing belt to simplify the structure, the processed surface layer is transferred through the workbench and the side panels are welded to the mattress body from top to bottom. While improving the processing efficiency, the side panels are adjusted and trimmed through the workbench, thereby improving the yield of the inflatable mattress.

[0041] 2. The first surface layer and the second surface layer in this solution are welded to the reinforcing tape and the drawing body respectively, and internal and external indentations are formed at the connection points. While ensuring the connection strength, the presence of breakpoints and relative positions on the indentations can be used to determine whether there is a possibility of pressure leakage and wrong welding, thereby improving the product yield.

[0042] The specific embodiments described herein are merely illustrative of the spirit of the present invention. Persons skilled in the art may make various modifications, additions, or substitutions to the described specific embodiments without departing from the spirit of the present invention or exceeding the scope defined by the appended claims.

Claims

1. A method for manufacturing a wire drawing air mattress, the mattress comprising a wire drawing body (1), a first surface layer (21), a second surface layer (22) and a side skirt (3) formed by cutting, the side skirt (3) being provided with an air pump (5) and an air nozzle (3a1), the end of the side skirt (3) being connected to the first surface layer (21) or the second surface layer (22) via a reinforcing strip (4b) and the outer side surface of the first surface layer (21) or the second surface layer (22), the manufacturing method comprising the following steps: S1, welding the outer edges of the first surface layer (21) and the second surface layer (22) to the reinforcing strip (4b) respectively, and trimming the reinforcing strip (4b) to control the corresponding size; S2, welding the first surface layer (21) and the second surface layer (22) to the wire drawing body (1) to form a mattress body, and cutting and controlling the sizes of the first surface layer (21) and the second surface layer (22); S3, welding one side of the cut first surface layer (21) to the outer side of the upper end of the side panel (3) via the reinforcing strip (4b), and directly welding the other side to the inner side of the upper end of the side panel (3); S4. Welding the outer side of the lower end of the side enclosure (3) to the reinforcing strip (4b) located on the second surface layer (22), and directly welding the inner side of the lower end of the side enclosure (3) to the second surface layer (22).

2. The method for manufacturing a wire drawing air mattress according to claim 1, characterized in that: After step S1, the method further includes: checking whether there is a pressure leak or a fold somewhere, and if so, placing it in a disqualified area.

3. The method for manufacturing a wire drawing air mattress according to claim 1, characterized in that: The reinforcing strip (4b) is respectively connected to the first surface layer (21) or the second surface layer (22) by welding using high-frequency welding equipment, and an external indentation (4d) is formed on the reinforcing strip (4b).

4. The method for manufacturing a wire drawing air mattress according to claim 1, characterized in that: Step S2 comprises: after the first surface layer (21) and the second surface layer (22) are laid flat, the wire drawing body (1) is welded to the first surface layer (21) and the second surface layer (22) by high-frequency welding equipment, and internal indentations (4c) are formed on the first surface layer (21) and the second surface layer (22).

5. The method for manufacturing a wire drawing air mattress according to claim 1, characterized in that: Before step S3, the method further includes: drawing a line on the side panel (3), fixing the air nozzle (3a1) to the side panel (3), and then opening an air pump hole (5b) on the side panel (3), and pressing the air pump (5) into the side panel (3) through a mold.

6. The method for manufacturing a wire drawing air mattress according to claim 5, characterized in that: After cutting, the side panels (3) are marked and lined at locations where holes need to be opened, and the air nozzles (3a1) are passed through the side panels (3) for welding.

7. The method for manufacturing a wire drawing air mattress according to claim 6, characterized in that: The side panel (3) is removed, and an air pump hole (5b) is opened on the side panel (3). Then, the air pump (5) is fixed to the side panel (3) through the air pump hole (5b) using a mold.

8. The method for manufacturing a wire drawing air mattress according to claim 1, characterized in that: After step S4, the method further includes: checking whether the finished product has appearance defects, and placing the finished product in a defective product area if there are appearance defects.

9. A wire drawing air mattress, comprising a wire drawing body (1), two surface layers (2) and side surrounds (3) wrapping the wire drawing body (1), wherein both ends of the two surface layers (2) are welded to the side surrounds (3), and characterized in that: The outer edges of the two surface layers (2) are welded to a connecting belt (4) which is overlapped and connected with the side enclosure (3), the connecting belt (4) comprising a bonding belt (4a) and a reinforcing belt (4b), the side enclosure (3) partially overlaps with the bonding belt (4a), and the reinforcing belt (4b) covers the overlapping position, so that the end of the side enclosure (3) can be clamped and connected between the bonding belt (4a) and the reinforcing belt (4b).

10. The wire drawing air mattress according to claim 9, characterized in that: One end of the bonding tape (4a) is connected to the surface layer (2), and one end of the reinforcing tape (4b) is welded to the bonding tape (4a).

11. The wire drawing air mattress according to claim 9 or 10, characterized in that: An inner indentation (4c) and an outer indentation (4d) are provided at the connection position between the connection belt (4) and the surface layer (2); the inner indentation (4c) is formed by welding the bonding belt (4a) to the surface layer (2); and the outer indentation (4d) is formed by welding the bonding belt (4a) to the reinforcement belt (4b).

12. The wire drawing air mattress according to claim 9 or 10, characterized in that: The area of ​​the wire drawing body (1) is the same as the area of ​​the surface layer (2), and the two surface layers (2) are connected via the wire drawing body (1).

13. The wire drawing air mattress according to claim 9, characterized in that: The connecting belt (4) is connected to the two surface layers (2) and the side panels (3) by welding using high-frequency welding equipment.

14. The wire drawing air mattress according to claim 9, characterized in that: The drawn air-filled mattress is provided with an air pump (5), the side surround (3) is provided with an air hole (3a), the air hole (3a) is provided with an air nozzle (3a1), and the air nozzle (3a1) can cooperate with the air pump (5).

15. The wire drawing air mattress according to claim 9, characterized in that: The bonding tape (4a) and the reinforcing tape (4b) are formed by welding PVC material and PVC bonding fabric.

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