TWI788017B - 墊體及其製法 - Google Patents

墊體及其製法 Download PDF

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TWI788017B
TWI788017B TW110134672A TW110134672A TWI788017B TW I788017 B TWI788017 B TW I788017B TW 110134672 A TW110134672 A TW 110134672A TW 110134672 A TW110134672 A TW 110134672A TW I788017 B TWI788017 B TW I788017B
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foam layer
hardness
foam
joint surface
layer
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TW110134672A
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TW202313148A (zh
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布魯斯 艾倫 斯拉許
劉東安
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美商帕拉萊斯集團國際有限責任公司
劉東安
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Priority to TW110134672A priority Critical patent/TWI788017B/zh
Priority to US17/891,806 priority patent/US12011910B2/en
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Abstract

本發明關於一種墊體及其製法，該墊體包括：一第一發泡層，具有一第一硬度及一第一孔隙率；一第二發泡層，連接於該第一發泡層之一側，具有一第二硬度及一大於該第一孔隙率之第二孔隙率；及一第三發泡層，連接於該第二發泡層相對於該第一發泡層之一側，具有一大於該第一硬度及該第二硬度之第三硬度及一小於該第一孔隙率之第三孔隙率；其中，該第二發泡層包括一面向該第一發泡層之第一接合面及一面向該第三發泡層之第二接合面，該第一接合面與該第一發泡層之接觸面積相異於該第二接合面與該第三發泡層之接觸面積。

Description

墊體及其製法
本發明係與墊體有關，特別是有關於一種墊體及其製法。
習知之墊體依據使用目的不同，例如但不限作為瑜珈墊、遊戲墊、止滑墊等，一般會藉由材質及發泡程度之配合以符合各種功能性需求。為了增加厚度或其他使用需求，習知之墊體係藉由膠體將複數層體相互黏合而成，例如於一發泡層之一側黏接一止滑層，藉以使該墊體之一表面具有止滑效果。
然而，習知之該膠體易產生異味而造成使用感受不佳，且該墊體之製造過程較繁雜而導致製造成本高。此外，由於相鄰之二層體與該膠體之間的性質差異，易產生黏合強度不足之疑慮，且該二層體之接合面亦可能因該膠體而導致該墊體之局部硬度或壓縮率無法達到預期，存在亟待改善之缺弊。
因此，有必要提供一種新穎且具有進步性之墊體及其製法，以解決上述之問題。
本發明之主要目的在於提供一種墊體及其製法，無異味、易於製造且功能多樣化。
為達成上述目的，本發明提供一種墊體，包括：一第一發泡層，具有一第一硬度及一第一孔隙率；一第二發泡層，連接於該第一發泡層之一側，具有一不大於該第一硬度之第二硬度及一大於該第一孔隙率之第二孔隙率；及一第三發泡層，連接於該第二發泡層相對於該第一發泡層之一側，具有一大於該第一硬度之第三硬度及一小於該第一孔隙率之第三孔隙率；其中，該第二發泡層包括一面向該第一發泡層之第一接合面及一面向該第三發泡層之第二接合面，該第一接合面與該第一發泡層之接觸面積相異於該第二接合面與該第三發泡層之接觸面積。
為達成上述目的，本發明另提供一種如上所述之墊體之製法，包括以下步驟：發泡成型該第一發泡層、該第二發泡層及該第三發泡層；熱壓接合該第一發泡層及該第三發泡層其中一者與該第二發泡層；熱壓接合該第一發泡層及該第三發泡層另一者於該第二發泡層以形成一基材；及裁切該基材以形成至少一該墊體。
以下僅以實施例說明本發明可能之實施態樣，然並非用以限制本發明所欲保護之範疇，合先敘明。
請參考圖1至7，其顯示本發明之一較佳實施例，本發明之墊體1包括一第一發泡層10、一第二發泡層20及一第三發泡層30。
該第一發泡層10具有一第一硬度及一第一孔隙率；該第二發泡層20連接於該第一發泡層10之一側且具有一第二硬度及一大於該第一孔隙率之第二孔隙率；該第三發泡層30連接於該第二發泡層20相對於該第一發泡層10之一側且具有一大於該第一硬度及該第二硬度之第三硬度及一小於該第一孔隙率之第三孔隙率；其中，該第二發泡層20包括一面向該第一發泡層10之第一接合面21及一面向該第三發泡層30之第二接合面22，該第一接合面21與該第一發泡層10之接觸面積相異於該第二接合面22與該第三發泡層30之接觸面積。藉此，該第一發泡層10及該第三發泡層30之軟硬度不同而可依據需求選用，功能多樣化，且該第二發泡層20可提供良好的緩衝及減震效果。
該第一硬度、該第二硬度及該第三硬度係分別指該第一發泡層10、該第二發泡層20及該第三發泡層30之平均硬度。於本實施例中，以一C型硬度計測定，該第一硬度之數值範圍介於20至35；該第二硬度之數值範圍介於20至35；該第三硬度之數值大於40；其中該C型硬度計例如為TECLOCK C型硬度計（GS-701N），係依據SRIS標準規範可用於海綿、軟性橡膠、硬度小於A型20之發泡體之硬度檢測，檢測數值越大則硬度越大。於測量硬度時係量測已接合成型之該墊體1，舉例來說，該第一硬度約為30，其量測位置係該第一發泡層10背向該第二發泡層20之一表面，該第一發泡層10較柔軟而易受壓變形，可作為瑜珈墊使用，觸感舒適且緩衝效果佳；該第三硬度約為50，其量測位置係該第三發泡層30背向該第二發泡層20之一表面，該第三發泡層30之硬度較大且受壓時不易變形，可供放置重物（例如健身器材、機台等）以提供減震效果，穩定性佳；該第二硬度約為20，其量測位置係該第二發泡層20於該墊體1之一切面上朝外顯露之部分。詳細說，該第二發泡層20另包括一位於該第一接合面21及該第二接合面22之間之中間部分23，該第一接合面21及該第二接合面22至少其中一者之硬度大於該中間部分23之硬度，藉以與該第一發泡層10及該第二發泡層20穩定接合。於本實施例中，該墊體1周設有一組接結構40，藉此可相互拼接以適用不同使用面積，亦可以該第一發泡層10朝上或該第三發泡層30朝上之方式拼接以區分使用區域（如圖6所示），例如徒手運動區或器材區，布置方式多元且便利性佳。
由於該第一發泡層10及該第三發泡層30之硬度差異，當二者承受相同大小之壓力時，該第一發泡層10之形變範圍較深且窄，該第三發泡層30之形變範圍則較淺且廣。配合參考圖4，該第一接合面21與該第一發泡層10之接觸面積大於該第二接合面22與該第三發泡層30之接觸面積；該第二發泡層20鄰近於該第一接合面21之一側之密度大於該第二發泡層20鄰近於該第二接合面22之一側之密度，藉此該第一接合面21可順應該第一發泡層10之受力而變形，密合度佳且該第二發泡層20可供壓縮以減少硬度落差。該第二發泡層20包括複數封閉性之孔洞24，該複數孔洞24至少部分於該第二接合面22上朝該第三發泡層30開放，藉此當該第三發泡層30受壓時，該第二發泡層20可藉由該複數孔洞24壓縮變形，變形裕度充足而不易因硬度差異過大而相互剝離，同時可避免局部凹陷，支撐性佳。
該第二發泡層20之厚度不小於該第一發泡層10之厚度且小於該第三發泡層30之厚度。詳細說，該第三發泡層30之厚度為該第二發泡層20之厚度的至少兩倍，於使用時穩定性及減震效果佳；該第二發泡層20之厚度為該第一發泡層10之厚度的至少兩倍，緩衝效果佳。然，該第一發泡層、該第二發泡層及該第三發泡層之厚度亦可依需求調整。
於本實施例中，該第一發泡層10及該第三發泡層30之材質皆包括聚乙烯（polyethylene，PE）及乙烯醋酸乙烯酯共聚物（ethylene vinyl acetate copolymer，EVA），該第一發泡層10之PE含量小於該第三發泡層30之PE含量，藉以生成硬度相異之發泡結構；該第一發泡層10之EVA含量大於該第三發泡層30之EVA含量，藉此該第一發泡層10可提供極佳的止滑效果；該第二發泡層20之材質包括PE，易於調整軟硬度及厚度、回彈力佳且重量輕。要特別說明的是，當該第三發泡層30朝上而以該第一發泡層10接觸一置放面時，該第一發泡層10可於該墊體1受力時提供更佳之止滑效果；舉例來說，於該第三發泡層30上放置健身器材時，由於該墊體1承受器材重量而增加下壓力，該第一發泡層10與該置放面之間之摩擦力增加而不易受力移動，安全性佳。較佳地，該第一發泡層10及該第三發泡層30皆為封閉式發泡結構，不易變形且防水效果佳；該第二發泡層20之熔點低於該第一發泡層10及該第三發泡層30之熔點，藉此於加工時僅需加熱熔融該第一接合面21及該第二接合面22即可與該第一發泡層10及該第三發泡層30相互貼合，無需使用接著劑且可避免該第一發泡層10及該第三發泡層30之結構受加熱而改變，加工穩定性佳。該第一發泡層10、該第二發泡層20及該第三發泡層30亦可另外添加無機填料（例如碳酸鈣）以增加加工穩定性。於其他實施例中，該第一發泡層、該第二發泡層及該第三發泡層亦可依需求選用其他材質，或添加染色劑、增塑劑等。
該第一發泡層10包括複數色塊11，該複數色塊11包括至少二種相異之顏色且混雜地相互嵌接，藉以提供特殊之視覺效果，美觀性佳。該第一發泡層10相對於該第二發泡層20之一表面設有一壓紋結構12，止滑效果及觸感佳。於其他實施例中，該第一發泡層亦可由單一顏色之薄片構成。配合參考圖5，該第三發泡層30包括一相對於該第二發泡層20之接觸面31，該接觸面31設有彎曲延伸之複數第一凹溝311及複數第二凹溝312，該複數第一凹溝311至少部分橫向於該複數第二凹溝312延伸；該複數第一凹溝311相互並排形成複數第一單元313，該複數第二凹溝312相互並排形成複數第二單元314，該複數第一單元313與該複數第二單元314相互交錯排列，止滑效果及美觀性佳。然，該複數第一凹溝及該複數第二凹溝亦可配置為波浪狀、多角形、幾何結構等。
本發明另提供一種如上所述之墊體1之製法，包括以下步驟。步驟S1：發泡成型該第一發泡層10、該第二發泡層20及該第三發泡層30；步驟S2：熱壓接合該第一發泡層10及該第三發泡層30其中一者與該第二發泡層20；步驟S3：熱壓接合該第一發泡層10及該第三發泡層30另一者於該第二發泡層20以形成一基材；及步驟S4：裁切該基材以形成至少一該墊體1。
於該步驟S1中之發泡形成該第一發泡層10，另包括以下步驟：備一模具；放置複數原料顆粒於該模具中，其中該複數顆粒包括至少二種相異之顏色，該複數原料顆粒例如包括PE樹脂顆粒及EVA樹脂顆粒；加熱熔融該複數原料顆粒並發泡成型為一發泡體；及自該模具取出該發泡體並依據一預定厚度平切為至少一該第一發泡層10。藉此，僅藉由單次發泡即可獲得多個該第一發泡層10，易於製造且發泡結構緻密、防水性佳且耐磨耗，且該複數色塊11隨機排列而構成獨特之外觀。
於本實施例中，該第二發泡層20係連續發泡成型，藉以製得尺寸較大之該複數孔洞24且該第二發泡層20之發泡結構較蓬鬆，可壓縮性佳；該第三發泡層30係模壓發泡成型，以具有緻密的發泡結構，硬度高、防水性佳且耐磨耗；該第二發泡層20係先與該第一發泡層10接合後，再將該第三發泡層30接合於該第二發泡層20相對於該第一發泡層10之一側。舉例來說，於該步驟S2中，該第一發泡層10可先對準該第一接合面21，並以一加熱機構（例如熱風槍）加熱熔融該第一接合面21，接著再將該第一發泡層10與該第二發泡層20同時通過一滾壓機構以相互壓合，由於該第一發泡層10及該第二發泡層20可撓性較佳，因此結合後仍可捲收，便於後續操作；同樣地，於該步驟S3中，該第三發泡層30可先對準該第二接合面22，並以該加熱機構加熱熔融該第二接合面22，接著再將第三發泡層30及已結合之該第一發泡層10與該第二發泡層20同時通過該滾壓機構，即可構成該基材。於其他實施例中，該第二發泡層亦可先與該第三發泡層接合，再與該第一發泡層接合；亦可加熱熔融該第一發泡層或該第三發泡層以與該第一接合面或該第二接合面相互熔接。
1:墊體 10:第一發泡層 11:色塊 12:壓紋結構 20:第二發泡層 21:第一接合面 22:第二接合面 23:中間部分 24:孔洞 30:第三發泡層 31:接觸面 311:第一凹溝 312:第二凹溝 313:第一單元 314:第二單元 40:組接結構 S1~S4:步驟
圖1為本發明一較佳實施例之立體圖。 圖2為本發明一較佳實施例之分解圖。 圖3為本發明一較佳實施例之另一分解圖。 圖4為本發明一較佳實施例之局部放大圖。 圖5為圖1之局部放大圖。 圖6為本發明一較佳實施例之使用示意圖 圖7為本發明一較佳實施例之步驟流程圖。
1:墊體
31:接觸面
40:組接結構

Claims (14)

  1. 一種墊體，包括：一第一發泡層，具有一第一硬度及一第一孔隙率；一第二發泡層，連接於該第一發泡層之一側，具有一第二硬度及一大於該第一孔隙率之第二孔隙率；及一第三發泡層，連接於該第二發泡層相對於該第一發泡層之一側，具有一大於該第一硬度及該第二硬度之第三硬度及一小於該第一孔隙率之第三孔隙率；其中，該第二發泡層包括一面向該第一發泡層之第一接合面及一面向該第三發泡層之第二接合面，該第一接合面與該第一發泡層之接觸面積相異於該第二接合面與該第三發泡層之接觸面積；其中，該第二發泡層包括複數封閉性之孔洞，該複數孔洞至少部分於該第二接合面上朝該第三發泡層開放。
  2. 如請求項1所述的墊體，其中該第一接合面與該第一發泡層之接觸面積大於該第二接合面與該第三發泡層之接觸面積。
  3. 如請求項1所述的墊體，其中該第二發泡層鄰近於該第一接合面之一側之密度大於該第二發泡層鄰近於該第二接合面之一側之密度。
  4. 如請求項1所述的墊體，其中該第二發泡層之厚度不小於該第一發泡層之厚度且小於該第三發泡層之厚度。
  5. 如請求項4所述的墊體，其中該第三發泡層之厚度為該第二發泡層之厚度的至少兩倍。
  6. 如請求項1所述的墊體，其中該第二發泡層另包括一位於該第一接合面及該第二接合面之間之中間部分，該第一接合面及該第二接合面至少其中一者之硬度大於該中間部分之硬度。
  7. 如請求項1所述的墊體，其中該第一發泡層包括複數色塊，該複數色塊包括至少二種相異之顏色且混雜地相互嵌接。
  8. 如請求項1所述的墊體，其中該第三發泡層包括一相對於該第二發泡層之接觸面，該接觸面設有彎曲延伸之複數第一凹溝及複數第二凹溝，該複數第一凹溝至少部分橫向於該複數第二凹溝延伸。
  9. 如請求項5所述的墊體，其中該第一發泡層及該第三發泡層之材質皆包括聚乙烯(polyethylene，PE)及乙烯醋酸乙烯酯共聚物(ethylene vinyl acetate copolymer，EVA)，該第一發泡層之PE含量小於該第三發泡層之PE含量；該第二發泡層之材質包括PE；該第一發泡層之EVA含量大於該第三發泡層之EVA含量；該第二發泡層之材質包括PE；該第二發泡層之厚度為該第一發泡層之厚度的至少兩倍；該第一接合面與該第一發泡層之接觸面積大於該第二接合面與該第三發泡層之接觸面積；該第二發泡層鄰近於該第一接合面之一側之密度大於該第二發泡層鄰近於該第二接合面之一側之密度；該第一發泡層及該第三發泡層皆為封閉式發泡結構；該第二發泡層另包括一位於該第一接合面及該第二接合面之間之中間部分，該第一接合面及該第二接合面至少其中一者之硬度大於該中間部分之硬度；該第二發泡層之熔點低於該第一發泡層及該第三發泡層之熔點；以一C型硬度計測定，該第一硬度之數值範圍介於20至35；該第二硬度之數值範圍介於20至35；該第三硬度之數值大於40；該第一發泡層包括複數色塊，該複數色塊包括至少二種相異之顏色且混雜地相互嵌接；該第三發泡層包括一 相對於該第二發泡層之接觸面，該接觸面設有彎曲延伸之複數第一凹溝及複數第二凹溝，該複數第一凹溝至少部分橫向於該複數第二凹溝延伸；該複數第一凹溝相互並排形成複數第一單元，該複數第二凹溝相互並排形成複數第二單元，該複數第一單元與該複數第二單元相互交錯排列；及該第一發泡層相對於該第二發泡層之一表面設有一壓紋結構。
  10. 一種如請求項1至9任一項所述的墊體之製法，包括以下步驟：發泡成型該第一發泡層、該第二發泡層及該第三發泡層；熱壓接合該第一發泡層及該第三發泡層其中一者與該第二發泡層；熱壓接合該第一發泡層及該第三發泡層另一者於該第二發泡層以形成一基材；及裁切該基材以形成至少一該墊體。
  11. 如請求項10所述的製法，其中於發泡形成該第一發泡層之步驟中，另包括以下步驟：備一模具；放置複數原料顆粒於該模具中，其中該複數顆粒包括至少二種相異之顏色；加熱熔融該複數原料顆粒並發泡成型為一發泡體；及自該模具取出該發泡體並依據一預定厚度平切為至少一該第一發泡層。
  12. 如請求項10所述的製法，其中該第二發泡層係連續發泡成型。
  13. 如請求項10所述的製法，其中該第三發泡層係模壓發泡成型。
  14. 如請求項10所述的製法，其中該第二發泡層係先與該第一發泡層接合後，再將該第三發泡層接合於該第二發泡層相對於該第一發泡層之一側。
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