WO2009002119A1

WO2009002119A1 - Air mat and manufacturing method thereof

Info

Publication number: WO2009002119A1
Application number: PCT/KR2008/003719
Authority: WO
Inventors: Dongil Kim
Original assignee: Individual
Current assignee: Individual
Priority date: 2007-06-28
Filing date: 2008-06-27
Publication date: 2008-12-31
Anticipated expiration: 2009-12-28
Also published as: KR100820564B1

Abstract

An air mat includes a plurality of footing members (110) and a plurality of bearing members (120). The footing members (110) are provided at a predetermined width in a longitudinal direction through a footing member feeder (210). The bearing members (120) are provided in a direction perpendicular to the footing members (110) through a bearing member feeder (230) with contact surfaces (121) thereof fused by a heater (220), pressed by rotation of the footing member feeder (210) and the bearing member feeder (230), and causing the footing members (110) to be thermally bonded to the contact surfaces (121).

Description

Description AIR MAT AND MANUFACTURING METHOD THEREOF

Technical Field

[1] The present invention relates to an air mat and a manufacturing method thereof and, more particularly, to an air mat, which is made of flexible polyvinyl chloride (PVC) pipes, thereby having a cushion function based on elastic force of the PVC pipe and preventing slipping on a wet floor, and a method of manufacturing the same. Background Art

[2] In general, mats serve to be placed immediately outside or inside the entrance to a building to allow people to scrub or wipe the soles of their shoes before entering or placed on the wet floor of a bathroom or a swimming pool to allow people to walk thereon. Further, the mats, which are placed on the floor so as to enable people to walk without wearing shoes inside the building, are typically manufactured using wood or plastic.

[3] However, in the case in which this mat is installed at a wet place, particularly, on a wet floor, it slips on the floor due to moisture, which results in injury to people. In order to avoid this situation, a separate anti-slip device must be directly installed on the floor, which is a troublesome job.

[4] Further, in the case in which the mat is installed at a wet place such as a swimming pool, a bathroom, a rest room, or the like, water covered on the mat is not rapidly dried, and thus causes the sole of a foot to become wet when the mat is used. In the case in which the mat is made of wood, it is decomposed and destroyed when used for a long time. In the case in which the mat is made of plastic, it is frequently adhered using an adhesive, and furthermore this adhesive is harmful to a human body due to its toxic ingredients.

[5] Thus, in order to solve this problem, a mat is disclosed in Korean Utility Model Registration No. 20-0371322.

[6] FIGS. 1 and 2 are a perspective view and an enlarged detailed cross-sectional view illustrating a conventional mat (disclosed in Korean Utility Model Registration No. 20-0371322).

[7] As illustrated in FIG. 1, the conventional mat 10 is configured to dispose bearing members 11 shaped of a polyvinyl chloride (PVC) pipe at regular intervals, and to densely dispose footing members 12 shape of a PVC pipe on the bearing members 11, wherein heat and ultrasonic waves are applied to contact surfaces of the bearing members 11 and the footing members 12 so as to be bonded to each other.

[8] However, as illustrated in FIG. 2, the conventional mat 10 has a troublesome process in which the heat must be applied to the contact surfaces of the bearing members 11 and the footing members 12.

[9] Further, in the case in which the heat is applied to the contact surfaces in this way, the contact surfaces of the bearing members 11 and the footing members 12 are fused by the heat, and are changed from a hard state to a soft state. In this state, when mutually pressed, the contact surfaces of the bearing members 11 and the footing members 12 become thin, and thus are ruptured. As a result, a cushion function using air contained in the PVC pipe-shaped rods is reduced. Disclosure of Invention Technical Problem

[10] The present invention has been made to solve the foregoing problems with the prior art, and therefore embodiments of the present invention provide an air mat and a method of manufacturing the same, in which among the contact surfaces of the bearing and footing members, heat is applied only to the contact surface of each bearing member such that the bearing and footing members are bonded to each other, thereby simplifying a process of manufacturing the air mat.

[11] There is provided an air mat and a method of manufacturing the same, in which a rupture -proof ridge is provided to an inner circumference of each bearing member corresponding to a heated contact surface of each bearing member, thereby preventing the contact surface of each bearing member from being ruptured by pressure -bonding of the footing members although the contact surface of each bearing member is fused to become soft. Technical Solution

[12] In an exemplary embodiment of the present invention, the air mat may include a plurality of footing members (110) provided at a predetermined width in a longitudinal direction through a footing member feeding means (210); and a plurality of bearing members (120) provided in a direction perpendicular to the footing members (110) through a bearing member feeding means (230) with contact surfaces (121) thereof fused by a heating means (220), and pressed by rotation of the footing member feeding means (210) and the bearing member feeding means (230), thereby causing the footing members (110) to be thermally bonded to the contact surfaces (121).

[13] In another exemplary embodiment of the present invention, the footing members

(110) and the bearing members (120) may be shaped of a flexible polyvinyl chloride (PVC) pipe.

[14] In another exemplary embodiment of the present invention, each of the bearing members (120) may include a rupture-proof ridge (122) formed on an inner circumference thereof corresponding to the contact surface (121) thereof such that the contact surface (121) is not ruptured when fused by the heating means (220) and pressed for bonding of each of the footing members (110).

[15] In another exemplary embodiment of the present invention, the method of manufacturing an air mat may include the steps of: fitting a plurality of footing members (110) into footing member grooves (212), which are formed in a footing member roller (211) of a footing member feeding means (210), and feeding the footing members (110) into a predetermined gap between a bearing member roller (231) of a bearing member feeding means (230) and the footing member roller (211) in a longitudinal direction with a predetermined width; fitting a plurality of bearing members (120) into bearing member grooves (232), which are formed in the bearing member roller (231) of the bearing member means (230), and feeding the bearing members (120) into the gap between the bearing member roller (231) and the footing member roller (211) in a direction perpendicular to the footing members (110); lowering a heating means (220) from above the bearing member roller (231) to heat and fuse contact surface (121) of each of the bearing members (120) fitted into each of the bearing member grooves (232); and pressing the footing members (110) fed from the footing member roller (211) and the bearing members (120) that are fed from the bearing member roller (231) and are fused by heating of the heating means (220) by rotation of the footing member roller (211) and the bearing member roller (231) in contact with each other in the gap between the footing member roller (211) and the bearing member roller (231), and bonding the footing members (110) to the contact surfaces (121) of the bearing members (120).

Advantageous Effects

[16] According to exemplary embodiments of the present invention, among the contact surfaces of the bearing and footing members, heat is applied only to the contact surface of each bearing member, so that the bearing and footing members are bonded to each other. Thus, the process of manufacturing the air mat can be simplified.

[17] Further, the rupture-proof ridge is provided to the inner circumference of each bearing member corresponding to the heated contact surface of each bearing member, so that the contact surface of each bearing member can be prevented from being ruptured by heating and pressure-bonding of the footing members.

Brief Description of the Drawings

[18] FIGS. 1 and 2 are a perspective view and an enlarged detailed cross-sectional view illustrating a conventional mat.

[19] FIG. 3 is a perspective view illustrating an air mat according to an exemplary embodiment of the present invention.

[20] FIG. 4 is a perspective view illustrating a bearing member in the air mat of FIG. 3. [21] FIG. 5 is an enlarged detailed cross-sectional view illustrating the state in which bearing members are bonded to footing members in the air mat of FIG. 3.

[22] FIG. 6 is a side view illustrating a process of manufacturing the air mat of FIG. 3.

Mode for the Invention

[23] Hereinafter, an exemplary embodiment of the present invention will be described in detail with reference to the accompanying drawings.

[24] FIG. 3 is a perspective view illustrating an air mat according to an exemplary embodiment of the present invention. FIG. 4 is a perspective view illustrating a bearing member in the air mat of FIG. 3. FIG. 5 is an enlarged detailed cross-sectional view illustrating the state in which bearing members are bonded to footing members in the air mat of FIG. 3. FIG. 6 is a side view illustrating a process of manufacturing the air mat of FIG. 3.

[25] First, as illustrated in FIGS. 3-6, the air mat according to an exemplary embodiment of the present invention includes a plurality of footing members 110 and a plurality of bearing members 120. The footing members 110 are provided at a predetermined width in a longitudinal direction through a footing member feeding means 210. The bearing members 120 are provided in a direction perpendicular to the longitudinal direction of the footing members 110 through a bearing member feeding means 230 at a predetermined interval with contact surfaces 121 thereof fused by a heating means 220, and are pressed by rotation of the footing member feeding means 210 and the bearing member feeding means 230, thereby causing the footing members 110 to undergo thermal bonding to the contact surfaces 121.

[26] Here, each of the footing and bearing members 110 and 120 is preferably shaped of a flexible polyvinyl chloride (PVC) pipe.

[27] Further, as illustrated in FIGS. 4 and 5, each bearing member 120 is provided with a rupture-proof ridge 122 on an inner circumference thereof in a longitudinal direction corresponding to the contact surface 121 thereof such that the contact surface 121 thereof is ruptured by pressure with which the footing members 110 are pressed toward the contact surface 121 thereof which is fused by the heating means 220 and is thus converted from a hard state into a soft state.

[28] This rupture-proof ridge 122 increases a thickness of the contact surface 121 of each bearing member. Thus, when the footing members 110 are pressed toward the contact surfaces 121 of the bearing members 120 which are fused by the heating means 220, the surface area of the contact surface 121 of each bearing member is increased, and the thickness of the contact surface 121 of each bearing member is decreased. Even in this case, the contact face 121 of each bearing member is not ruptured, so that a yield of production can be improved, and a cushion function using an air layer in the PVC pipe can be prevented from being reduced.

[29] Further, the heating means 220 does not heat both the footing members 110 and the bearing members 120, but only the contact surfaces 121 of the bearing members 120. Thereby, the manufacturing process can be simplified, and the expenses caused by the configuration of the heating means 220 can be reduced.

[30] Hereinafter, a method of manufacturing the air mat, shown in FIG. 6, according to an exemplary embodiment of the present invention, and effects thereof will be described.

[31] First, the footing members 110 are fitted into footing member grooves 212, which are formed in a footing member roller 211 of the footing member feeding means 210, so as to be fed in a longitudinal direction with a predetermined width, and then are fed while facing a bearing member roller 231 of the bearing member feeding means 230, wherein the bearing member roller 231 is spaced apart from the footing member roller 211 with a predetermined gap.

[32] Then, the bearing members 120 are fitted into bearing member grooves 232, which are formed in the bearing member roller 231 of the bearing member feeding means 230 in a direction perpendicular to the longitudinal direction of the footing members 110, and then are fed while facing the footing member roller 211.

[33] Afterwards, the heating means 220 is lowered from the upper side of the bearing member roller 231, and then heats and fuses the contact surface 121 of each of the bearing members 120 fitted into the bearing member grooves 232.

[34] Here, each bearing member 120 is preferably fed by a tray or a conveyer belt such that the contact surface 121 thereof is oriented upwards with respect to the bottom of each bearing member groove 232 so as to allow the contact surface 121 thereof corresponding to the rupture-proof ridge 122 to be heated by the heating means 220.

[35] Further, each bearing member 120 is preferably fitted into each bearing member groove 232 such that the contact surface 121 thereof is oriented upwards with respect to the bottom of each bearing member groove 232 when fed by the tray (not designated by a reference number) or the conveyer belt of the bearing member feeding means 230 so as to allow the contact surface 121 thereof to be heated by the heating means 220.

[36] Afterwards, the footing members 110 fed to the footing member roller 211, and the bearing members 120 fed to the bearing member roller 231 in the state in which the bearing members 120 are fused by the heating of the heating means 220, are mutually pressed by rotation of the footing member roller 211 and the bearing member roller 231 in contact with each other through the gap between the footing member roller 211 and the bearing member roller 231, so that the footing members 110 are bonded to the contact surfaces 121 of the bearing members 120.

[37] Preferably, the gap between the footing member roller 211 and the bearing member roller 231 is slightly greater than an outer diameter of the footing member roller 211 or the bearing member roller 231.

[38] Thus, the footing members 110 and the bearing members 120 fused by the heating of the heating means 220 are fed together into the gap between the footing member roller 211 and the bearing member roller 231, wherein the gap between the two rollers has such a distance that either the footing member 110 or the bearing member 120 can pass through the gap. Thereby, the footing members 110 and the bearing members 120 are pressed by the rotation of the footing member roller 211 and the bearing member roller 231 while being in contact with each other, and thus can be bonded to each other.

[39] As described above, according to the exemplary embodiment of the present invention, the footing members are bonded to the bearing members, which are arranged at regular intervals, with a predetermined width in a grid shape, so that the mat can be manufactured. Among the contact surfaces of the bearing and footing members, heat is applied only to the contact surface of each bearing member when the bearing and footing members are bonded to each other, so that the process of manufacturing the mat can be simplified.

[40] Further, the rupture-proof ridge is provided to the inner circumference of each bearing member corresponding to the heated contact surface of each bearing member, so that the contact surface of each bearing member can be prevented from being ruptured by pressure-bonding of the footing members although the contact surface of each bearing member is heated and fused into a soft state. Further, the rupture-proof ridge can improve an air cushion function using the air confined in the footing members and the bearing members.

[41] Further, the footing members are shaped of a pipe. Thus, although the mat is installed at a wet place, the moisture can rapidly flow downwards, and thus be easily dried to prevent slipping.

[42] In the drawings and specification, typical exemplary embodiments of the invention have been disclosed, and although specific terms are employed, they are used in a generic and descriptive sense only and are not for the purposes of limitation, the scope of the invention being set forth in the following claims.

Claims

[1] An air mat, comprising: a plurality of footing members (110) provided at a predetermined width in a longitudinal direction through a footing member feeding means (210); and a plurality of bearing members (120) provided in a direction perpendicular to the footing members (110) through a bearing member feeding means (230) with contact surfaces (121) thereof fused by a heating means (220), and pressed by rotation of the footing member feeding means (210) and the bearing member feeding means (230), thereby causing the footing members (110) to be thermally bonded to the contact surfaces (121).

[2] The air mat as set forth in claim 1, wherein the footing members (110) and the bearing members (120) are shaped of a flexible polyvinyl chloride (PVC) pipe.

[3] The air mat as set forth in claim 2, wherein each of the bearing members (120) includes a rupture-proof ridge (122) formed on an inner circumference thereof corresponding to the contact surface (121) thereof such that the contact surface (121) is not ruptured when fused by the heating means (220) and pressed for bonding of each of the footing members (110).

[4] A method of manufacturing an air mat, comprising: fitting a plurality of footing members (110) into footing member grooves (212), which are formed in a footing member roller (211) of a footing member feeding means (210), and feeding the footing members (110) into a predetermined gap between a bearing member roller (231) of a bearing member feeding means (230) and the footing member roller (211) in a longitudinal direction with a predetermined width; fitting a plurality of bearing members (120) into bearing member grooves (232), which are formed in the bearing member roller (231) of the bearing member feeding means (230), and feeding the bearing members (120) into the gap between the bearing member roller (231) and the footing member roller (211) in a direction perpendicular to the footing members (110); lowering a heating means (220) from above the bearing member roller (231) to heat and fuse contact surface (121) of each of the bearing members (120) fitted into each of the bearing member grooves (232); and pressing the footing members (110) fed from the footing member roller (211) and the bearing members (120) that are fed from the bearing member roller (231) and are fused by heating of the heating means (220) by rotation of the footing member roller (211) and the bearing member roller (231) in contact with each other in the gap between the footing member roller (211) and the bearing member roller (231), and bonding the footing members (110) to the contact surfaces (121) of the bearing members (120).