KR102205270B1 - Buffer mats and their manufacturing methods - Google Patents

Buffer mats and their manufacturing methods Download PDF

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KR102205270B1
KR102205270B1 KR1020180081056A KR20180081056A KR102205270B1 KR 102205270 B1 KR102205270 B1 KR 102205270B1 KR 1020180081056 A KR1020180081056 A KR 1020180081056A KR 20180081056 A KR20180081056 A KR 20180081056A KR 102205270 B1 KR102205270 B1 KR 102205270B1
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South Korea
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sponge
film
manufacturing
electron beam
heat
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KR1020180081056A
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Korean (ko)
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KR20200007216A (en
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곽훈종
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(주)대산케미텍
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/06—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the heating method
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47C—CHAIRS; SOFAS; BEDS
    • A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
    • A47C27/14—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C59/00—Surface shaping of articles, e.g. embossing; Apparatus therefor
    • B29C59/02—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing
    • B29C59/022—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing characterised by the disposition or the configuration, e.g. dimensions, of the embossments or the shaping tools therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/065—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/40—Layered products comprising a layer of synthetic resin comprising polyurethanes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/0004—Cutting, tearing or severing, e.g. bursting; Cutter details
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/06—Embossing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2471/00—Floor coverings
    • B32B2471/04—Mats

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Laminated Bodies (AREA)
  • Buffer Packaging (AREA)

Abstract

본 발명은, 내구성과 내충격성 및 흡음성 등이 매우 우수하고 외관이 미려하게 되어 상품성을 대폭 향상시켜 줌은 물론 다양한 용도에 안전하게 사용할 수 있도록 하는 완충매트 및 그 제조방법에 관한 것이다.
이와 같은 본 발명에 따른 완충매트 및 그 제조방법은, PE스펀지(11)의 하면에 PE필름(12)을 밀접시켜 열융착하여 하부재(10)를 제조하는 제1공정과, PE전자선가교스펀지(21)의 상면에 TPU우레탄필름(22)을 밀접시켜 열융착하여 상부재(20)를 제조하는 제2공정 및 상기 하부재의 상면에 상부재의 하면을 밀접시켜 열융착하는 과정에서 PE필름과 TPU우레탄필름에 요철형의 다양한 표면무늬나 돌기(30)를 형성하는 제3공정을 포함하여 구성되는 것을 특징으로 하는 것이다.The present invention relates to a cushioning mat and a method for manufacturing the same, which significantly improves the product properties due to excellent durability, impact resistance, sound absorption, and the like, and a beautiful appearance, as well as to be safely used for various purposes.
The buffer mat and its manufacturing method according to the present invention include a first process of manufacturing the lower material 10 by heat-sealing the PE film 12 in close contact with the lower surface of the PE sponge 11, and the PE electron beam crosslinking sponge. PE film in the second process of manufacturing the upper material 20 by closely bonding the TPU urethane film 22 to the upper surface of (21) and heat-sealing the upper material 20, and in the process of thermally bonding the lower surface of the upper material to the upper surface of the lower material. And a third process of forming various uneven surface patterns or projections 30 on the TPU urethane film.

Description

완충매트 및 그 제조방법{Buffer mats and their manufacturing methods}Buffer mats and their manufacturing methods

본 발명은 완충매트 및 그 제조방법에 관한 것으로서, 더욱 상세하게는 내구성과 내충격성 및 흡음성 등이 매우 우수하고 외관이 미려하게 되어 상품성을 대폭 향상시켜 줌은 물론 다양한 용도에 안전하게 사용할 수 있도록 하는 완충매트 및 그 제조방법에 관한 것이다.The present invention relates to a cushioning mat and a method of manufacturing the same, and more particularly, it has excellent durability, impact resistance, and sound absorption, and has a beautiful appearance, which significantly improves the marketability and can be safely used for various purposes. It relates to a mat and a manufacturing method thereof.

종래에는, 도 1a에서와 같이 에틸렌과 초산비닐 모노머를 공중합시켜 얻어지는 중합체(EVA)인 스펀지를 필요한 두께로 열압착시켜 단일체로 형성되는 매트가 있었는데, 이러한 매트는 두께를 얇게 하면 자체의 탄성은 물론 내구성이 약화되어 잘 찢어지거나 쉽게 파손되는 현상이 초래되므로 이를 감안하여 두께를 최대한도에서 두껍게 제조하였기 때문에 중량이 무거워 취급 및 유지관리가 매우 어렵게 되는 등의 문제점이 있었다.Conventionally, there has been a mat formed into a single body by thermocompressing a sponge, which is a polymer (EVA) obtained by copolymerizing ethylene and vinyl acetate monomers to a required thickness, as shown in FIG. 1A. When the thickness is reduced, the mat is not only elastic. Since the durability is weakened, it causes a phenomenon that it is easily torn or damaged, so there is a problem in that handling and maintenance are very difficult because the weight is heavy because the thickness is manufactured as thick as possible in consideration of this.

또한, 도 1b에서와 같이 소정두께의 PE발포수지로 형성되는 하부재(1)와, 소정두께의 EVA로 형성되며 상기 하부재의 상면에 열압착되어 일체로 접합되는 상부재(2)로 구성되는 매트도 있었는데, 이러한 매트는 저렴한 비용으로 제작할 수 있는 반면에 역시 중량이 무겁게 되는 것임은 물론 상·하부재가 모두 스펀지재질이므로 내구성이 약하고 상부재는 취약하여 잘 찢어지기 때문에 뛰고 노는 어린이의 놀이판 등으로 사용하기에는 매우 부적합하였으며, 수명단축이 초래되어 재료와 관련비용의 낭비가 유발되는 등의 문제점들이 있었다.In addition, as shown in Fig. 1b, it is composed of a lower material (1) formed of a PE foam resin having a predetermined thickness, and an upper material (2) formed of EVA of a predetermined thickness and bonded integrally by heat compression bonding to the upper surface of the lower material. There were also mats that could be manufactured at low cost, but the weight was also heavy, and the upper and lower members were both made of sponge, so the durability was weak, and the upper material was fragile and easily torn, so it was used as a play board for children who run and play. It was very unsuitable for use, and there were problems such as shortening of the lifespan and waste of materials and related costs.

또한, 도 1c에서와 같이 하부재(1)와 상부재(2)가 모두 PE발포수지로 형성되어 열압착되어 일체로 접합 구성되는 매트도 있었는데, 이러한 매트 역시 상·하부재가 모두 스펀지재질로 되는 것이므로 재질적 차이를 크게 극복하지 못하기 때문에 도 1a,b의 완충매트와 같은 문제점들을 갖고 있었다.In addition, as shown in Fig. 1c, there was also a mat in which both the lower member 1 and the upper member 2 were formed of PE foamed resin and were heat-compressed to be integrally bonded. Such a mat was also made of sponge material. Therefore, it has the same problems as the buffer mats of FIGS. 1a and b because it cannot overcome the material difference greatly.

또한, 종래의 이러한 매트들은 표면처리가 미흡하고 미끄러워 상품성이 크게 저하됨과 동시에 어린이들이 뛰고 노는 과정에서 미끄러져 다치게 되는 등의 안전사고가 빈발하게 되었음은 물론 음식물 등의 이물질에 의해 표면이 쉽게 오염되어 미관을 손상시키게 되는 등의 문제점들도 있었다.In addition, such conventional mats have insufficient surface treatment and are slippery, so their marketability is greatly degraded. At the same time, safety accidents such as slipping and injuries during the running and playing process of children have become frequent, and the surface is easily contaminated by foreign substances such as food. There were also problems, such as damage to the aesthetics.

본 발명은 종래의 이러한 점들을 감안하여 발명된 것으로서, 그 목적은 내구성과 내충격성 등이 매우 우수하고 표면을 미려하고도 미끄럽지 않도록 처리함으로써 수명단축 방지와 충격흡수 및 흡음 효과 등은 물론 안전성과 상품성도 대폭 향상시켜 줌과 동시에 다양한 용도에 안전하게 사용할 수 있도록 하는 완충매트 및 그 제조방법을 제공하는 것이다.The present invention has been invented in consideration of these priorities, and its purpose is to prevent shortening of life, absorb shock and sound absorption by treating the surface so that it is very excellent in durability and impact resistance and not slippery, as well as safety and product It is to provide a buffer mat and a manufacturing method thereof that can be used safely for various purposes while greatly improving the performance.

본 발명은 이러한 목적을 달성하기 위해, 소정두께로 발포되는 PE스펀지와 두께가 얇은 PE필름을 각각 원하는 규격으로 재단한 다음 상기 PE스펀지의 하면에 PE필름을 밀접시켜 열융착하여 이루어지는 하부재를 제조하는 제1공정과, 전자선가교발포폴리에틸렌폼으로 되는 소정두께의 PE전자선가교스펀지와 두께가 얇은 TPU우레탄필름을 각각 상기 하부재에 대응하는 규격으로 재단한 다음 상기 PE전자선가교스펀지의 상면에 TPU우레탄필름을 밀접시켜 열융착하여 이루어지는 상부재를 제조하는 제2공정 및 상기 하부재의 상면에 상부재의 하면을 밀접시켜 열융착하는 과정에서 PE필름과 TPU우레탄필름에 요철형의 다양한 표면무늬나 엠보싱 돌기를 형성하여 이루어지는 완충매트를 제조하는 제3공정으로 구성되는 것을 특징으로 하는 것이다.In order to achieve this object, the present invention manufactures a lower material formed by cutting a PE sponge foamed to a predetermined thickness and a PE film having a thin thickness to a desired standard, and then heat-sealing the PE film in close contact with the lower surface of the PE sponge. In the first process, a PE electron beam crosslinking sponge of a predetermined thickness and a thin TPU urethane film made of an electron beam crosslinking foam polyethylene are cut to a standard corresponding to the lower material, and then TPU urethane on the upper surface of the PE electron beam crosslinking sponge. In the second process of manufacturing an upper material formed by heat-sealing the film in close contact with the upper material, and in the process of heat-sealing the upper material by closely contacting the upper surface of the lower material with the upper surface of the lower material, various uneven surface patterns or embossing on PE film and TPU urethane film It is characterized by consisting of a third step of manufacturing a buffer mat formed by forming projections.

이와 같은 본 발명에 따른 제조방법에 의해 제조되는 완충매트는, 내구성과 내충격성 등이 매우 우수하여 수명단축 방지와 충격흡수 및 흡음 효과가 극대화됨은 물론 표면이 미려하고 미끄럽지 않게 처리되어 어린이들이 뛰고 놀 때 미끄러지지 않도록 함으로써 상품성과 안전성이 대폭 향상됨과 동시에 다양한 용도에 안심하고 사용할 수 있도록 하는 등의 효과도 얻게 된다.The cushioning mat manufactured by the manufacturing method according to the present invention has excellent durability and impact resistance, so that it prevents shortening of life and maximizes shock absorption and sound absorption effects, as well as the beautiful and non-slip surface that children can play and play. By preventing slippage, the marketability and safety are greatly improved, and at the same time, it is possible to safely use it for various purposes.

도 1a~c는 종래 매트의 각기 다른 예를 일부 발췌확대하여 보인 측면도
도 2는 본 발명에 따른 완충매트의 일부를 보인 사시도
도 3a~e는 본 발명 제조방법에 따른 완충매트의 제조공정을 보인 측면도1A to 1C are side views showing enlarged excerpts of different examples of conventional mats
Figure 2 is a perspective view showing a part of the buffer mat according to the present invention
3A to 3E are side views showing the manufacturing process of the buffer mat according to the manufacturing method of the present invention

이하, 본 발명에 따른 완충매트를 첨부된 도면에 의거하여 상세하게 설명하면 다음과 같다.Hereinafter, a buffer mat according to the present invention will be described in detail with reference to the accompanying drawings.

도 2는 본 발명에 따른 완충매트의 일부를 보인 사시도이다.2 is a perspective view showing a part of the buffer mat according to the present invention.

도 2의 본 발명에 따른 완충매트는, 소정두께로 발포되는 PE스펀지(11)와 상기 PE스펀지의 하면에 열융착되는 PE필름(12)으로 형성되는 하부재(10)와, 친환경재질인 전자선가교발포폴리에틸렌폼으로 되는 소정두께의 PE전자선가교스펀지(21)와 상기 PE전자선가교스펀지의 상면에 열융착되는 친환경재질인 TPU우레탄필름(22)으로 형성되는 상부재(20)와, 상기 하부재의 PE스펀지 상면과 상부재의 PE전자선가교스펀지 하면을 밀접시켜 한 몸체로 되게 열융착하는 과정에서 상기 PE필름과 TPU우레탄필름에 요철형의 다양한 표면무늬나 엠보싱 돌기(30)를 형성하여 구성되는 것을 특징으로 한다.The buffer mat according to the present invention of FIG. 2 includes a PE sponge 11 foamed to a predetermined thickness, a lower material 10 formed of a PE film 12 heat-sealed to the lower surface of the PE sponge, and an eco-friendly electron beam. An upper material 20 formed of a PE electron beam crosslinking sponge 21 of a predetermined thickness made of crosslinked foamed polyethylene foam and a TPU urethane film 22, an eco-friendly material that is thermally fused to the upper surface of the PE electron beam crosslinking sponge, and the lower material In the process of heat-sealing the upper surface of the PE sponge and the lower surface of the PE electron beam crosslinking sponge of the upper material into one body, various surface patterns or embossing protrusions 30 are formed on the PE film and the TPU urethane film. It features.

하부재(10)와 상부재(20)는, 그 두께를 서로 동일하게 하거나 서로 다르게 하여도 되며, 용도 등 필요에 따라서는 완충매트 자체의 두께는 물론 면적을 다르게 할 수도 있다.The lower member 10 and the upper member 20 may have the same or different thickness from each other, and may have different areas as well as the thickness of the buffer mat itself, depending on the needs such as use.

도 3a~e는 본 발명 제조방법에 따른 완충매트의 제조공정을 보인 측면도이다.3A to 3E are side views showing the manufacturing process of the buffer mat according to the manufacturing method of the present invention.

도 3a,b는 하부재(10)를 제조하는 제1공정으로서, 소정두께로 발포되는 PE스펀지(11)와, 상기 PE스펀지 보다 두께가 얇게 형성되는 PE필름(12)을 각각 원하는 규격으로 동일하게 재단한 다음, 상기 PE스펀지의 하면에 PE필름을 밀접시켜 열융착하여 이루어진다.3A and 3B are the first process of manufacturing the lower material 10, wherein the PE sponge 11 foamed to a predetermined thickness and the PE film 12 formed thinner than the PE sponge are each of the same desired standard. Then, the PE film is in close contact with the lower surface of the PE sponge and heat-sealed.

이렇게 하면, PE스펀지(11)와 PE필름(12)이 동일성향의 재질이므로 서로 견고하게 열융착되어 한 몸체가 된다.In this way, since the PE sponge 11 and the PE film 12 are materials of the same orientation, they are firmly thermally fused together to form one body.

이렇게 융착되는 PE필름(12)은, PE스펀지(11)의 하면을 피복하여 보호하게 되므로 하부재(10)의 강도와 내구성을 대폭 향상시켜 주게됨과 동시에 쉽게 찢어지거나 파단되는 현상이 초래되지 않도록 한다.The PE film 12 fused in this way is protected by covering the lower surface of the PE sponge 11, thus greatly improving the strength and durability of the lower material 10, and at the same time preventing the phenomenon of being easily torn or broken. .

이렇게 함으로써 수명단축이 방지되며, 이에 따라 재료 및 관련비용의 낭비 등이 발생하지 않게 한다.This prevents shortening of the lifespan, thereby preventing waste of materials and related costs.

도 3c,d는 상부재(20)를 제조하는 제2공정으로서, 친환경재질인 전자선가교발포폴리에틸렌폼으로 되는 소정두께의 PE전자선가교스펀지(21)와, 상기 PE전자선가교스펀지 보다 두께가 얇게 형성되는 TPU우레탄필름(22)을 각각 하부재(10)에 대응하는 규격으로 재단한 다음, 상기 PE전자선가교스펀지의 상면에 TPU우레탄필름을 밀접시켜 열융착하여 이루어진다.3c and d are a second process for manufacturing the upper material 20, a PE electron beam crosslinking sponge 21 of a predetermined thickness made of an eco-friendly electron beam crosslinking foam polyethylene foam, and a thickness thinner than the PE electron beam crosslinking sponge The TPU urethane film 22 is cut into a standard corresponding to each of the lower material 10, and then the TPU urethane film is in close contact with the upper surface of the PE electron beam crosslinking sponge and heat-sealed.

이때, PE전자선가교스펀지(21)와 TPU우레탄필름(22)은 열융착성이 양호한 재질이므로 서로 견고하게 융착되어 한 몸체가 된다.At this time, since the PE electron beam crosslinking sponge 21 and the TPU urethane film 22 are a material having good heat sealing properties, they are firmly fused together to form one body.

이렇게 융착되는 TPU우레탄필름(22)은, PE전자선가교스펀지(21)의 상면을 피복하여 보호하게 되므로 상부재(20)의 강도와 내구성을 대폭 향상시켜 줌과 동시에 쉽게 찢어지거나 파단되는 현상이 초래되지 않도록 하며, 이에 따라 수명단축이 방지되어 재료 및 관련비용의 낭비 등이 발생하지 않게 된다.Since the TPU urethane film 22 fused in this way covers and protects the upper surface of the PE electron beam crosslinking sponge 21, it greatly improves the strength and durability of the upper material 20, and at the same time, it is easily torn or broken. This prevents shortening of the life span, and thus waste of materials and related costs does not occur.

또한, PE전자선가교스펀지(21)는 종횡으로 교차하게 그물 모양으로 발포되는 상태의 구조로 되는 것이므로, 탄성이 우수하여 반복되는 충격에도 내구성이 유지됨은 물론 것임은 물론 상부의 진동이나 충격음이 하부로 갈수록 고르게 분산되어 감쇄되도록 한다.In addition, since the PE electron beam crosslinking sponge 21 has a structure in a state of being foamed in a net shape crossing vertically and horizontally, it has excellent elasticity and maintains durability even against repeated impacts, as well as vibration or impact sound from the top to the bottom. It is distributed evenly as it becomes more and more attenuated.

도 3e는 하부재(10)의 상면에 상부재(20)의 하면을 열융착하여 완충매트를 제조하는 제3공정으로서, 상기 하부재의 PE스펀지(11) 상면에 상기 상부재의 PE전자선가교스펀지(21) 하면을 밀접시켜 열융착하여 이루어진다.3E is a third process of manufacturing a buffer mat by heat-sealing the lower surface of the upper member 20 to the upper surface of the lower member 10, and the PE electron beam crosslinking of the upper member on the upper surface of the PE sponge 11 of the lower member It is made by heat-sealing the sponge 21 in close contact with the lower surface.

이때, 상·하면이 밀접되는 PE스펀지(11)와 PE전자선가교스펀지(21)는 동일 성향의 재질이므로 서로 견고하게 열융착되어 한 몸체가 된다.At this time, since the PE sponge 11 and the PE electron beam crosslinking sponge 21, which are in close contact with the upper and lower surfaces, are made of the same material, they are heat-sealed firmly to form one body.

이와 같이, PE스펀지(11)의 하면에 PE필름(12)을 열융착한 하부재(10)와 PE전자선가교스펀지(21)의 상면에 TPU우레탄필름(22)을 열융착한 상부재(20)를 각각 별개로 제조한 다음 상기 상·하부재를 열융착하여 완충매트를 제조하는 것은, 상기 PE스펀지와 PE전자선가교스펀지를 먼저 열융착한 상태에서 이들의 하면과 상면에 각각 PE필름과 TPU우레탄필름을 열융착하는 것이 매우 어렵기 때문에 상·하부재를 각각 별도로 제작하여 동일성향의 재질인 PE스펀지와 PE전자선가교스펀지를 이용하여 신속하고도 용이하게 한 몸체로 되도록 융착하기 위한 것이다.In this way, the lower material 10 obtained by heat-sealing the PE film 12 on the lower surface of the PE sponge 11 and the upper material 20 obtained by heat-sealing the TPU urethane film 22 on the upper surface of the PE electron beam crosslinking sponge 21. ) Separately, and then heat-sealing the upper and lower members to produce a buffer mat, in which the PE sponge and the PE electron beam crosslinking sponge are first heat-sealed, and then a PE film and a TPU on their lower and upper surfaces, respectively. Since it is very difficult to heat-seal the urethane film, it is to make the upper and lower members separately so that they can be quickly and easily formed into one body using PE sponge and PE electron beam crosslinking sponge, which are materials of the same orientation.

한편, 하부재(10)와 상부재(20)를 열융착하는 과정에서 PE필름(12)과 TPU우레탄필름(22)에 요철형의 다양한 표면무늬나 엠보싱 돌기(30)를 동시에 형성한다.On the other hand, in the process of heat-sealing the lower material 10 and the upper material 20, various surface patterns or embossing protrusions 30 of uneven shape are simultaneously formed on the PE film 12 and the TPU urethane film 22.

이렇게 형성되는 요철형의 표면무늬나 엠보싱 돌기(30)들은, PE필름(12) 및 TPU우레탄필름(22)이 각각 PE스펀지(11) 및 PE전자선가교스펀지(21)와의 접합력을 더욱 향상시켜 주므로 장기간 사용하여도 쉽게 박리되지 않도록 한다.The uneven surface pattern or embossing protrusion 30 formed in this way further improves the bonding strength of the PE film 12 and the TPU urethane film 22 with the PE sponge 11 and the PE electron beam crosslinking sponge 21, respectively. Do not peel off easily even after long-term use.

또한, 요철형의 표면무늬나 엠보싱 돌기(30)들에 의해 표면에서 미끄럼이 발생하는 것이 효과적으로 방지되기 때문에 어린이들이 뛰고 놀 때 미끄러져 안전사고가 유발되지 않도록 하여 안심하고 사용할 수 있도록 한다.In addition, since the occurrence of slipping on the surface is effectively prevented by the uneven surface pattern or the embossing protrusions 30, it is possible to use it with confidence by preventing a safety accident by slipping when children run and play.

또한, PE필름(12)과 TPU우레탄필름(22)에 의해 표면강도의 향상과 미려한 표면처리는 물론 음식물 등에 의해 표면이 오염되는 경우에 물걸레 등으로 간편하게 닦아낼 수 있게 되어 상품성을 크게 향상시켜 주게 된다.In addition, the PE film 12 and the TPU urethane film 22 improve the surface strength and have a beautiful surface treatment, as well as when the surface is contaminated by food, etc., it can be easily wiped off with a water rag, greatly improving the marketability. do.

또한, 위층에서 발생되는 진동 또는 충격음 등의 흡수 및 흡음기능이 매우 우수하여 진동 또는 충격음이 전달되는 것을 효과적으로 차단할 수 있게 되어 층간소음된다.In addition, since the absorption and sound absorption functions of vibration or impact sound generated from the upper layer are very excellent, it is possible to effectively block the transmission of vibration or impact sound, thereby making interlayer noise.

이와 같은 본 발명에 따른 완충매트는, 표면이 친환경재질인 TPU우레탄필름(22)으로 되어 인체에 무해함은 물론 PE스펀지(11)와 PE전자선가교스펀지(21)의 두께 조절이 매우 용이하여 어린이용 퍼즐매트나 접이식 폴더매트 또는 실내용 바닥매트나 요가매트로는 물론 층간에서 발생하는 진동 또는 충격음 등이 전달되는 것이 효과적으로 차단돠어 층간소음방지용 방진매트 등의 다양한 용도에 적용할 수 있게 되는 특징도 있다.The buffer mat according to the present invention is made of a TPU urethane film 22, which is an eco-friendly material, and is harmless to the human body, and the thickness of the PE sponge 11 and the PE electron beam crosslinking sponge 21 is very easy. There is also a feature that can be applied to a variety of uses, such as a puzzle mat, folding folder mat, indoor floor mat, yoga mat, as well as vibration or impact sound generated between floors, is effectively blocked, and can be applied to a variety of purposes, such as a vibration-proof mat for preventing inter-floor noise. .

10 : 하부재 11 : PE스펀지
12 : PE필름
20 : 상부재 21 : PE전자선가교스펀지
22 : TPU우레탄필름
30 : 표면무늬나 돌기10: lower material 11: PE sponge
12: PE film
20: upper material 21: PE electron beam crosslinking sponge
22: TPU urethane film
30: surface pattern or projection

Claims (2)

소정두께로 발포되는 PE스펀지(11)와 상기 PE스펀지(11) 보다 두께가 얇은 PE필름(12)을 각각 원하는 규격으로 재단한 다음, 상기 PE스펀지(11)의 하면에 PE필름(12)을 밀접시켜 열융착하여 하부재(10)를 제조하는 제1공정과;
전자선가교발포폴리에틸렌폼으로 되는 소정두께의 PE전자선가교스펀지(21)와 상기 PE전자선가교스펀지(21) 보다 두께가 얇은 TPU우레탄필름(22)을 상기 하부재(10)에 대응하는 규격으로 재단한 다음, 상기 PE전자선가교스펀지(21)의 상면에 TPU우레탄필름(22)을 밀접시켜 열융착하여 상부재(20)를 제조하는 제2공정; 및
상기 하부재(10)의 상면에 상부재(20)의 하면을 밀접시켜 열융착하는 과정에서 PE필름(12)과 TPU우레탄필름(22)에 요철형의 다양한 표면무늬나 엠보싱 돌기(30)를 형성하는 제3공정을 포함하여 구성되는 것을 특징으로 하는 완충매트의 제조방법.A PE sponge 11 foamed to a predetermined thickness and a PE film 12 thinner than the PE sponge 11 are cut to a desired size, respectively, and then a PE film 12 is placed on the lower surface of the PE sponge 11. A first process of manufacturing the lower material 10 by heat fusion in close contact;
A PE electron beam crosslinking sponge 21 of a predetermined thickness made of electron beam crosslinking foam polyethylene foam and a TPU urethane film 22 that is thinner than the PE electron beam crosslinking sponge 21 are cut to a standard corresponding to the lower material 10. Next, a second process of manufacturing the upper material 20 by heat-sealing the TPU urethane film 22 in close contact with the upper surface of the PE electron beam crosslinking sponge 21; And
In the process of heat-sealing the upper surface of the upper member 20 to the upper surface of the lower member 10, various uneven surface patterns or embossing protrusions 30 are formed on the PE film 12 and the TPU urethane film 22. A method of manufacturing a buffer mat, characterized in that it comprises a third step of forming. 삭제delete
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