Seamless quilt, manufacturing process for seamless quilt, and adhesive coating apparatus

Abstract

The present application discloses a seamless quilt, a manufacturing process for the seamless quilt, and an adhesive coating apparatus. The seamless quilt comprises an upper layer, a lower layer, and a core material wrapped between the upper layer and the lower layer; the upper layer and the lower layer are each provided with a plurality of corresponding predetermined areas; the predetermined areas of the lower layer are each provided with dense adhesive dots formed by using a dispensing machine to dispense an adhesive; the upper layer and the lower layer are adhesively fixed to each other through the core material at each predetermined area. In the present application, for the product form of the seamless quilt, by providing the predetermined areas and dispensing the adhesive at the predetermined areas by using the dispensing machine, the shapes of the predetermined areas, the density of the adhesive dots, and the amount of the adhesive can be flexibly changed, thereby achieving flexible design of the seamless quilt.

Description

A seamless quilt, a seamless quilt manufacturing process and an adhesive coating device Technical Field

[0001] This application discloses a seamless quilt, a seamless quilt manufacturing process, and an adhesive application device, relating to the field of home furnishing product technology. Background Technology

[0002] Quilts are common household products. Conventional quilts use stitching to fix the quilt material and internal core materials such as fillings. With long-term use, the needle holes will inevitably enlarge, causing the filling to leak out or dust to get in.

[0003] To improve user experience and lifespan, the industry has developed seamless quilt products. The quilt material and internal core are fixed together using seamless methods such as adhesive bonding, welding, and ultrasonic welding. Because this seamless quilt design requires a seamless fixing method, the top and bottom layers often have to be fixed to the filling material in the middle section, as seen in Chinese patent CN202775408U, entitled "A Seamless Quilt with Iron-on Printed Finish." This results in the remaining filling material not fixed to the top and bottom layers lacking restraint and easily shifting.

[0004] To address the issue of internal core material limitation, Chinese patent CN119453709A, entitled "A Seamless Blanket, Seamless Blanket Manufacturing Process and Manufacturing Apparatus," describes a method where adhesive is applied to a specific area to connect and fix the upper and lower layers through the core material. The adhesive application method used is roller application. This method has the following drawbacks: 1. The amount of adhesive applied by roller application is difficult to control; 2. Once the roller is manufactured, the applied area is fixed in position and cannot be changed during use. Summary of the Invention

[0005] The technical problem this application aims to solve is how to more accurately control the amount of adhesive applied in seamless processing and how to flexibly change the shape and position of the adhesive application area.

[0006] To solve the above-mentioned technical problems, the technical solution of this application provides a seamless coating, including an upper layer, a lower layer, and a core material wrapped between the upper layer and the lower layer; the upper layer and the lower layer are provided with a number of corresponding predetermined areas, and the predetermined areas of the lower layer are provided with dense dot-shaped adhesive formed by dispensing machine, and the upper layer and the lower layer are glued and fixed through the core material in the predetermined areas.

[0007] Preferably, the edge of the lower layer is provided with a ring of dense dot-shaped adhesive formed by dispensing machine, and the edges of the upper layer and the lower layer are glued and fixed to seal and enclose the core material.

[0008] Preferably, the core material is a prefabricated integral core material.

[0009] Preferably, the core material has a perforation corresponding to the predetermined area, and the upper layer and the lower layer are glued and fixed through the perforation in the predetermined area to form a connection, the connection being used to limit the core material.

[0010] Preferably, the integral core material is a composite structure, including multiple composite layers; the multiple composite layers are made of materials with different elasticity, different breathability, different heat retention capacity, or different loft.

[0011] Preferably, the dot-shaped colloid includes a moisture-curing adhesive or a hot melt adhesive.

[0012] Preferably, the density of the dense dot-shaped colloid in different predetermined areas is set to be the same or different, and the amount of colloid in the dot-shaped colloid is set to be the same or different in different predetermined areas.

[0013] Preferably, the distribution of the predetermined area on the lower layer and the shape of the predetermined area are defined by the dense dot-shaped adhesive formed by the dispensing machine. The shape of the predetermined area includes square, rhombus, flower, strip, circle, ellipse, T-shape, Y-shape, etc.

[0014] The technical solution of this application also provides a coating device for making a seamless blanket. The coating device includes a flattening table for laying the lower layer flattening and a three-dimensional dispensing machine disposed on the flattening table. The three-dimensional dispensing machine has a degree of freedom of movement in the X and Y directions parallel to the flattening table and a degree of freedom of lifting in the Z direction perpendicular to the flattening table. The lower layer is laid flattening on the flattening table, and the three-dimensional dispensing machine drips adhesive into the predetermined area to form dense dot-shaped adhesive.

[0015] The technical solution of this application also provides a seamless blanket manufacturing process. The seamless blanket to be manufactured includes an upper layer, a lower layer, and a core material wrapped between the upper layer and the lower layer. The upper layer and the lower layer are provided with a number of corresponding predetermined areas. The above-mentioned adhesive applicator is used to drop adhesive onto the predetermined areas of the lower layer to form a dense dot-shaped adhesive. The upper layer and the lower layer are bonded and fixed through the core material in the predetermined areas to form a seamless blanket.

[0016] This application targets the seamless quilt product form. By setting a predetermined area and applying adhesive through a dispensing machine in the predetermined area, the shape of the predetermined area and the density and amount of adhesive dots can be flexibly changed, thus realizing the flexible design of the seamless quilt. Attached Figure Description

[0017] Figure 1 is a schematic diagram of the seamless hierarchical structure provided in the embodiments of this application;

[0018] Figure 2 is a schematic diagram of the predetermined area distribution provided in the embodiments of this application;

[0019] Figure 3 is a schematic diagram of the predetermined area dispensing provided in the embodiment of this application;

[0020] Figure 4 is a schematic diagram of the lower layer edge dispensing provided in the embodiment of this application;

[0021] Figure 5 is a schematic diagram of the integrated core material composite structure provided in the embodiment of this application;

[0022] Figure 6 is a schematic diagram of the adhesive application device provided in the embodiment of this application;

[0023] Figure 7 is a second schematic diagram of the adhesive application device provided in the embodiments of this application;

[0024] Explanation of reference numerals in the attached diagram: Top layer 100, Bottom layer 200, Core material 300, Weak elastic layer 300-1, Elastic layer 300-2, Pre-defined area 400, Dotted adhesive 401, Flatbed 500, 3D dispensing machine 600. Detailed Implementation

[0025] To make this application more apparent and understandable, various exemplary embodiments will be described below. These examples are non-limiting and should be understood as illustrating aspects of the broader application of the apparatus, system, and method. These embodiments can be varied and substituted with equivalents without departing from the spirit and scope of this application. Furthermore, various variations can be made to adapt to specific circumstances, materials, material compositions, processing types, processing actions, or steps to suit the purpose, content, or scope of this application. All such variations will be within the protection scope of this application.

[0026] Any materials, dimensions, or quantities described in the overview or detailed description are merely examples and are not intended to limit the subject matter of this application. Furthermore, the various implementations of the embodiments described herein are complementary rather than purely alternating, unless otherwise stated. In other words, implementations from one embodiment can be freely combined with implementations from other embodiments, as will readily be apparent to those skilled in the art, unless these implementations are stated to be used only as substitutions.

[0027] In the description of this application, it should be noted that the terms "inner," "outer," "upper," "lower," "left," "right," "front," and "rear," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship commonly used when the product is in use. They are used only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application. In addition, the terms "first," "second," etc., are used only to distinguish descriptions and should not be construed as indicating or implying relative importance.

[0028] In the description of this application, it should also be noted that, unless otherwise expressly specified and limited, the terms "setup" and "connection" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a direct connection or an indirect connection through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in this application based on the specific circumstances.

[0029] Example 1

[0030] This application provides a seamless blanket, as shown in Figures 1 and 2, comprising an upper layer 100, a lower layer 200, and a core material 300 wrapped between the upper and lower layers. By setting a plurality of corresponding predetermined areas 400 in the upper layer 100 and the lower layer 200, as shown in Figure 3, dotted adhesive 401 formed by dispensing is provided on the predetermined areas 400. The dotted adhesive 401 is arrayed to form a dense dotted adhesive. The upper layer 100 and the lower layer 200 are glued and fixed through the core material 300 to form a seamless blanket with a three-layer structure.

[0031] The upper layer 100 and the lower layer 200 define the space for placing the core material 300. The upper layer 100 and the lower layer 200 can be two independent pieces of quilting material, which are respectively placed on the upper and lower sides of the core material 300 to wrap the core material 300; or they can be a whole piece of quilting material folded in half to form the upper layer 100 and the lower layer 200 that wrap the core material 300.

[0032] For example, the core material 300 can be an insulating medium that is filled between the upper layer 100 and the lower layer 200, such as common down, silk, wool, cotton, or fibers; or it can be a whole sheet of core material pre-made from the insulating medium, such as a latex sheet, a polyester fiber sheet, or a mixed material sheet. For non-integral core materials, the edges of the upper layer 100 and the lower layer 200 should be fixedly connected to enclose the core material 300; while for integral core materials, the edges of the upper layer 100 and the lower layer 200 can be intermittently fixedly connected, which can also serve to enclose the core material.

[0033] In a further embodiment, the predetermined area 400 includes an array of predetermined areas located in the center of the quilt surface. The shape can be square, rhomboid, floral, striped, circular, elliptical, T-shaped, Y-shaped, etc. Core material should be avoided in the predetermined area; that is, the core material should be left empty in the predetermined area so that the upper layer 100 and the lower layer 200 can pass through the empty space and be adhesively fixed to form a connection. The connection can be used to limit the core material. The predetermined areas 400 can be arrayed to form multiple arrayed connection points that limit the core material. For post-filled core material, the predetermined area 400 is naturally left empty, and the connection can be formed first, followed by filling the core material. For integral core material, holes should be pre-drilled in the predetermined area 400 before the upper layer 100 and the lower layer 200 are adhesively fixed to the predetermined area 400 to form a connection. This provides better limiting and fixing effect, and the integral core material is less likely to move.

[0034] For example, the upper layer 100 and the lower layer 200 are conventional fabrics, quilts, or textiles. The edges of the upper layer 100 and the lower layer 200 are seamlessly connected, as shown in Figure 4. The edge of the lower layer 200 facing the inner surface of the upper layer 100 is also provided with a ring of densely dotted adhesive formed by a dispensing machine. The edges of the upper layer 100 and the lower layer 200 are glued and fixed together, thereby sealing and encapsulating the core material 300. The fixed position of the edges of the upper layer 100 and the lower layer 200 is not limited to being tightly attached to the edge; it can also be located near the edge.

[0035] In a further embodiment, referring to Figure 5, the integrated core material 300 is a prefabricated component and a composite structure, including a double-layer composite. One layer is a weakly elastic layer 300-1, and the other is an elastic layer 300-2. The elasticity of the weakly elastic layer 300-1 is less than that of the elastic layer 300-2. The integrated core material is used behind a seamless quilt, so the two sides provide different sleeping experiences when the user sleeps, allowing the user to freely choose which side faces them. In addition to elasticity, layered structures with different breathability, different warmth retention, and different loft can also be provided to offer different sleeping experiences. Similarly, a multi-layered composite structure can be used, with each layer made of materials with different elasticity, breathability, warmth retention, or loft.

[0036] In a further embodiment, the dotted adhesive produced by the dispensing machine includes various types, such as UV-curable adhesives, hot melt adhesives, moisture-curing adhesives, silicone, and fast-drying adhesives. For process convenience, moisture-curing adhesives or hot melt adhesives are recommended. When using moisture-curing adhesives, after dispensing the lower layer 200, the core material 300 and the upper layer 100 should be laid on the lower layer 200 as soon as possible, and pressure should be maintained on the upper layer 100 and the lower layer 200 to keep them in contact until the moisture-curing adhesive cures. When using hot melt adhesives, after dispensing the lower layer 200 and laying the core material 300 and the upper layer 100 on the lower layer 200, in addition to maintaining pressure on the upper layer 100 and the lower layer 200, the adhesive also needs to be heated, for example, by heating the entire assembly using a heating table to melt the dotted adhesive and then adhesively fix the upper layer 100 and the lower layer 200.

[0037] It is understandable that the predetermined area 400 is not a physical concept. The distribution and shape of the predetermined area 400 on the lower layer 200 are determined during the seamless shaping process in the specific design. The relevant distribution and shape information are then input into the control program of the dispensing machine. The dense dot-like adhesive formed by the dispensing machine on the lower layer 200 defines the physical distribution and shape of the predetermined area 400. For predetermined areas 400 at different locations, the dispensing machine can form dot-like adhesive with different densities. For example, for predetermined areas 400 near the center of the quilt, a sparser dot-like adhesive can be formed, while for predetermined areas 400 near the edge of the quilt, a denser dot-like adhesive can be formed. Similarly, for predetermined areas 400 at different locations, dot-like adhesive with different amounts of adhesive can be formed to enhance local adhesive stability.

[0038] The seamless coating provided in this embodiment defines the solid shape and distribution of a predetermined area 400 by using a dotted adhesive formed by a dispensing machine, thus achieving flexibility in the predetermined area 400. Furthermore, by using a dispensing machine to form dotted adhesives of different densities or different amounts, this embodiment can achieve flexibility in the design of the seamless coating.

[0039] Example 2

[0040] This application also provides an adhesive applicator for making a seamless quilt, used to apply adhesive to the lower layer 200 of the seamless quilt in Example 1. Referring to Figures 6 and 7, the adhesive applicator includes a tiling table 500 for laying the lower layer 200 flat and a three-dimensional dispensing machine 600 disposed on the tiling table 500. The three-dimensional dispensing machine 600 is a device available in the prior art. It typically achieves horizontal planar movement through tracks in the X and Y directions to dispense adhesive at different positions, and uses a lifter in the Z direction to raise and lower the dispensing head to adapt to target objects of different thicknesses.

[0041] The lower layer 200 is laid flat on the tiling table 500. The distribution and shape information of the relevant predetermined area 400 are input into the control program of the three-dimensional dispensing machine 600 in advance. The three-dimensional dispensing machine 600 controls the dispensing head to drop and form dense dot-shaped glue in the predetermined area 400.

[0042] In a further embodiment, when the three-dimensional dispensing machine 600 forms dense dot-shaped colloids in a predetermined area of ​​400 dots, dot-shaped colloids with different densities and amounts are formed at different locations.

[0043] Example 3

[0044] This application also provides a process for manufacturing a seamless blanket using the aforementioned adhesive applicator. The seamless blanket to be manufactured includes an upper layer 100, a lower layer 200, and a core material 300 wrapped between the upper layer 100 and the lower layer 200. The upper layer 100 and the lower layer 200 are provided with a number of corresponding predetermined areas 400. The adhesive applicator provided in Embodiment 2 is used to drop dense dot-like adhesive on the lower layer 200 in the predetermined areas 400. Then, the core material 300 is laid on the lower layer 200, and the upper layer 100 is laid on the core material 300. The upper layer 100 is pressed down so that the upper layer 100 and the lower layer 200 pass through the core material 300 in the predetermined areas 400 and are glued and fixed.

[0045] It should be noted that the core material involved in the above process generally refers to prefabricated integrated core material, that is, sheet core material. The prefabricated integrated core material can be pre-drilled in a predetermined area of ​​400 mm.

[0046] The above description is merely a preferred embodiment of this application and does not constitute any limitation on this application in any form or substance. It should be noted that those skilled in the art can make several improvements and additions without departing from this application, and these improvements and additions should also be considered within the scope of protection of this application. Any modifications, alterations, and equivalent variations made by those skilled in the art based on the disclosed technical content without departing from the content and scope of this application are equivalent embodiments of this application. Furthermore, any equivalent changes, alterations, and variations made to the above embodiments based on the essential technology of this application still fall within the scope of the technical solution of this application.

Claims

1. A seamless quilt comprising an upper sheet, a lower sheet and a core material wrapped between the upper and lower sheets; the upper and lower sheets being provided with a plurality of predetermined areas corresponding to each other, characterized in that, The predetermined area of the lower layer is provided with intensive point-like glue formed by the glue dispenser, and the upper layer and the lower layer are glued and fixed through the core material at the predetermined area.

2. A seamless cover according to claim 1, wherein, The edge of the lower layer is provided with a ring of intensive point-like glue formed by the glue dispenser, and the edge of the upper layer and the edge of the lower layer are glued and fixed to enclose the core material.

3. A seamless cover according to claim 1, wherein, The core material is a prefabricated integrated core material.

4. A seamless bag according to claim 3, wherein, The core material is provided with perforations corresponding to the predetermined area, and the upper layer and the lower layer are glued and fixed through the perforations at the predetermined area to form a connecting part for limiting the core material.

5. A seamless bag according to claim 3, wherein, The integrated core material is a composite structure including multiple composite layers, and the multiple composite layers are made of materials with different elasticity, different air permeability, different warmth retention ability, or different loftiness.

6. A seamless bag according to claim 1, wherein, The point-like glue includes moisture-cured glue or hot melt glue.

7. A seamless bag according to claim 1, wherein The intensive degree of the intensive point-like glue at different predetermined areas is the same or different, and the amount of glue of the point-like glue at different predetermined areas is the same or different.

8. A seamless bag according to claim 1, wherein, The distribution of the predetermined area on the lower layer and the shape of the predetermined area are defined by the intensive point-like glue formed by the glue dispenser, and the shape of the predetermined area includes square, diamond, flower, strip, circle, ellipse, T shape, and Y shape.

9. A gluing device for manufacturing a seamless quilt, which glues a predetermined area of the lower layer of the seamless quilt according to any one of claims 1 to 8, characterized in that, The glue coating device includes a paving table for paving the lower layer and a three-dimensional glue dispenser provided on the paving table, the three-dimensional glue dispenser is provided with movement freedom in X direction and Y direction parallel to the paving table and lifting freedom in Z direction perpendicular to the paving table, the lower layer is paved on the paving table, and the three-dimensional glue dispenser forms intensive point-like glue at the predetermined area.

10. A seamless quilt manufacturing process, characterized in that, The seamless quilt to be manufactured includes an upper layer, a lower layer, and a core material wrapped between the upper layer and the lower layer, the upper layer and the lower layer are provided with corresponding predetermined areas, the glue coating device of claim 9 is used to form intensive point-like glue at the predetermined area of the lower layer, and the upper layer and the lower layer are glued and fixed through the core material at the predetermined area to form a seamless quilt.

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