Air Mat Molding With Integrated Air Pocket Bonding
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Solution Overview
Problem
Conventional air mat manufacturing methods using slush molding face challenges such as thick cushion parts, low bonding efficiency between the cushion and lower sheet, irregular air pocket thickness, and the need for separate communicating members, which increase production costs and complexity.
Innovation Solution
A method combining slush molding and rotational molding to create an air mat with a thinner cushion part, enhanced bonding between the cushion and lower sheet, and eliminating the need for separate communicating members by using scraps from the slush molding process as adhesive material during rotational molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If slush molding is used to manufacture the cushion part, then the cushion part can be formed with air pockets, but the cushion part becomes thick and requires separate communicating members
Solution Approach 1:
The patent combines slush molding and rotational molding into a single integrated process. The cushion part is first formed by slush molding with air pockets, then rotational molding is applied in the same mold to bond the lower sheet while simultaneously forming communicating passageways. This merging eliminates the need for separate communicating members and reduces cushion thickness.
Solution Approach 2:
The mold is designed to perform multiple functions: forming the cushion part with air pockets via slush molding, bonding the lower sheet via rotational molding, and creating communicating passageways. This multi-functionality eliminates the need for separate communicating members and reduces the overall cushion thickness required.
2Ease of manufacture
If the cushion part is molded with simple shape, then manufacturing is easier, but separate communicating passageway-forming process is required
Solution Approach 1:
The patent merges the cushion molding process with the communicating passageway formation process by applying rotational molding after slush molding within the same mold. This combination eliminates the need for a separate communicating passageway-forming process and improves manufacturing efficiency.
3Strength
If high-frequency bonding or adhesive bonding is used to bond the lower sheet, then bonding can be achieved, but manufacturing time increases and costs rise
Solution Approach 1:
The patent replaces high-frequency bonding or adhesive bonding with rotational molding. The lower sheet is bonded to the cushion part through rotational molding in the same mold, eliminating the need for separate bonding equipment and processes. This substitution reduces manufacturing time and costs while maintaining bonding strength.
4Ease of manufacture
If manual adhesive bonding is used, then bonding can be performed, but firm bonding is difficult to achieve and quality is low
Solution Approach 1:
The patent replaces manual adhesive bonding with rotational molding. The lower sheet and cushion part are bonded through the rotational molding process itself, which provides consistent and firm bonding without relying on manual operations. This substitution improves bonding quality and reliability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach results in improved bonding efficiency, uniform air pocket thickness, reduced material consumption, and simplified manufacturing processes, while increasing the cushion force and durability of the air mat.
Implementation Method 1
the filled plastic resin is externally poured out of the mold, and the resin layer coated to the predetermined thickness is completely gelled and cooled
Implementation Method 2
the resin layer coated to the predetermined thickness is completely gelled and cooled
Implementation Method 3
conducting a rotational molding process by rotating the lower mold coupled with the lower sheet and the cover thereon by means of a rotational molding machine, for bonding the cushion part and the lower sheet on the lower mold as an integral body
Implementation Method 4
conducting a rotational molding process by rotating the lower mold coupled with the lower sheet and the cover thereon
Data Source
AI summary
The present invention relates to a method for manufacturing an air mat that reduces a thickness of a cushion part by means of both slush molding and rotational molding, enhances a bonding efficiency between a lower sheet and the cushion part, and obviates the need of any separate communicating members for forming the communicating passageways for a plurality of air pockets of the cushion part, thereby simplifying manufacturing processes.