KR-102963254-B1 - method and apparatus for manufacturing air cap Sheet laminated cross-linked foam pad

KR102963254B1KR 102963254 B1KR102963254 B1KR 102963254B1KR-102963254-B1

Abstract

A device for manufacturing an air-cap laminated cross-linked foam pad is provided by laminating the air-cap sheet being molded with an additionally supplied cross-linked foam sheet while molding an air-cap sheet. The air-cap laminated cross-linked foam pad manufacturing device comprises: a resin discharge container extending along the width direction, having a first resin discharge slit hole and a second resin discharge slit hole formed at the bottom, extending long and parallel to each other along the width direction; a cross-linked foam sheet supply roller that maintains the cross-linked foam sheet in a roll shape and supplies the cross-linked foam sheet; and a molding roller installed to rotate directly below the resin discharge container, wherein a first resin discharged from the first resin discharge slit hole forms a lower resin layer on the outer surface, and a second resin discharged from the second resin discharge slit hole forms an upper resin layer on the lower resin layer, and an air-cap molding suction groove is formed on the outer surface to suction the lower resin layer to form a concave air-cap in the lower resin layer. and includes a pressure roller positioned closest to the outer circumference of the molding roller at a point different from the initial point where the first resin liquid and the second resin liquid meet the molding roller, wherein the pressure roller applies pressure to laminate the lower resin layer, the upper resin layer, and the cross-linked foam sheet when the cross-linked foam sheet supplied by being released from the cross-linked foam sheet supply roller is guided between the pressure roller and the molding roller, thereby laminating the air cap sheet formed by the lower resin layer and the upper resin layer with the cross-linked foam sheet.

Inventors

이윤희
정준규

Dates

Publication Date: 20260508
Application Date: 20240527

Claims (3)

In an apparatus for manufacturing an air-cap laminated cross-linked foam pad by forming an air-cap sheet and laminating the formed air-cap sheet with an additionally supplied cross-linked foam sheet, A resin liquid discharge container extending along the width direction, with a first resin liquid discharge slit hole and a second resin liquid discharge slit hole formed at the bottom, extending long and parallel to each other along the width direction; A cross-linked foam sheet supply roller that maintains the cross-linked foam sheet in a roll form and supplies the cross-linked foam sheet; A molding roller installed to rotate directly below the resin liquid discharge container, wherein a first resin liquid discharged from a first resin liquid discharge slit hole on the outer surface forms a lower resin layer, a second resin liquid discharged from a second resin liquid discharge slit hole forms an upper resin layer on the lower resin layer, and an air cap molding suction groove formed on the outer surface to suction the lower resin layer to form a concave air cap on the lower resin layer; and It includes a pressure roller positioned closest to the outer circumference of the molding roller at a point different from the initial point where the first resin liquid and the second resin liquid meet the molding roller, and An air cap laminated cross-linked foam pad manufacturing apparatus characterized by the above-mentioned pressure roller applying pressure to laminate the lower resin layer, the upper resin layer, and the cross-linked foam sheet when the cross-linked foam sheet supplied by being released from the cross-linked foam sheet supply roller is guided between the pressure roller and the molding roller, thereby laminating the air cap sheet formed by the lower resin layer and the upper resin layer with the cross-linked foam sheet.
In paragraph 1, An air cap laminated crosslinked foam pad manufacturing apparatus characterized in that the molding roller and the pressure roller are installed on a trolley arranged to be movable back and forth by a guide and a sliding roller, and the molding roller is positioned at either a position directly below the first resin liquid discharge slit hole and the second resin liquid discharge slit hole, or a position away from directly below the first resin liquid discharge slit hole and the second resin liquid discharge slit hole, by the back and forth movement of the trolley, and a heater is installed in the resin liquid discharge container.
A method for manufacturing an air-cap laminated cross-linked foam pad by using the air-cap laminated cross-linked foam pad manufacturing device of claim 1 or 2 to form an air-cap sheet, and laminating the formed air-cap sheet with an additionally supplied cross-linked foam sheet, wherein The trolley on which the molding roller is installed is moved to position the molding roller at a setting position directly below the first resin discharge slit hole and the second resin discharge slit hole formed at the bottom of the resin discharge container, and While rotating the above-mentioned forming roller and the corresponding pressure roller, the cross-linked foam sheet released and supplied from the cross-linked foam sheet supply roller is guided between the pressure roller and the forming roller, and The first resin liquid and the second resin liquid are discharged through the first resin liquid discharge slit hole and the second resin liquid discharge slit hole, so that the first resin liquid discharged from the first resin liquid discharge slit hole forms a lower resin layer on the outer surface of the molding roller, and the second resin liquid discharged from the second resin liquid discharge slit hole forms an upper resin layer on the lower resin layer. A suction is generated in the air cap molding suction groove formed on the molding roller, thereby forming a plurality of air caps in the lower resin layer that are blocked by the upper resin layer, and A method for manufacturing an air-cap laminated cross-linked foam pad, characterized by applying pressure so that when the cross-linked foam sheet is guided between the pressure roller and the molding roller, the lower resin layer with the air cap formed thereon, the upper resin layer, and the cross-linked foam sheet are laminated between the pressure roller and the molding roller.

Description

Method and apparatus for manufacturing air cap sheet laminated cross-linked foam pad The present invention relates to the manufacture of an air-cap laminated cross-linked foam pad, and more specifically, to a method and apparatus for manufacturing an air-cap laminated cross-linked foam pad by molding an air-cap sheet, particularly a PE (Polyethylene) air-cap sheet, and laminating the molded air-cap sheet with an additionally supplied cross-linked foam sheet, particularly a PE (Polyethylene) cross-linked foam sheet. Air cap sheets, particularly those formed from PE (Polyethylene) material, are used not only as cushioning packaging materials but also as insulation or cushioning materials due to their special structure containing multiple air caps called bubbles. However, while air bubble sheets possess many advantages as cushioning or insulating materials, their applications have been inevitably limited due to their disadvantages, such as being easily torn and deformed because of their low burst strength. For instance, it was difficult to use conventional air bubble sheets for high-strength sound-absorbing, sound-insulating, or cushioning purposes, or for other applications requiring high elasticity, cushioning, or high strength. For example, air bubble sheets can be considered as sound-absorbing or sound-insulating materials to prevent inter-floor noise in apartments or multi-unit dwellings; however, despite their various excellent performance characteristics, their application has been difficult due to low strength and poor durability. In this regard, a technology is proposed to manufacture a pad composed of a laminate of an air cap sheet and a cross-linked foam sheet by laminating the fabricated air cap sheet and the cross-linked foam sheet with an adhesive or the like. However, conventional technology has limitations in that it requires significant labor and costs due to multiple steps, resulting in poor economic efficiency and long manufacturing times. Furthermore, the bonding of the air cap sheet and the cross-linked foam sheet using an adhesive cannot achieve uniform adhesion, which can lead to easy separation of the two sheets. Additionally, the adhesive components cause modification of the air cap sheet and/or the cross-linked foam sheet, resulting in a reduction of the excellent properties possessed by each. FIG. 1 is a cross-sectional view illustrating an air bubble laminated cross-linked foam pad, and FIG. 2 is a configuration diagram for explaining, in its entirety, an air cap laminated cross-linked foam pad manufacturing apparatus for manufacturing the air cap laminated cross-linked foam pad illustrated in FIG. 1, and FIG. 3 is a drawing showing an enlarged portion of FIG. 2, and FIG. 4 is a bottom view illustrating a resin liquid discharge container having a first resin liquid discharge slit hole and a second resin liquid discharge slit hole formed therein, Figure 5 is a drawing illustrating a resin supply unit for supplying resin into a resin discharge container. Hereinafter, embodiments of the present invention will be described in detail with reference to the attached drawings so that those skilled in the art can easily implement the present invention. The present invention may be embodied in various different forms and is not limited to the embodiments described herein. In describing the present invention, the size or shape of the components shown in the drawings may be exaggerated or simplified for clarity and convenience of explanation. Furthermore, terms specifically defined in consideration of the structure and operation of the present invention may vary depending on the intent or practice of the user or operator. These terms should be interpreted in a meaning and concept consistent with the technical spirit of the present invention based on the content throughout this specification. To clearly explain the present invention, descriptions of parts unrelated to the technical concept of the present invention have been omitted, and the same reference numerals are used for identical or similar components throughout the specification. In addition, in various embodiments, components having the same configuration are described using the same reference numerals only in the representative embodiment, and in other embodiments, only configurations different from the representative embodiment are described. Throughout the specification, when a part is described as being "connected" to another part, this includes not only cases where they are "directly connected," but also cases where they are "indirectly connected" with other members in between. Furthermore, when a part is described as "including" a component, this may mean that it includes additional components rather than excluding other components, unless specifically stated otherwise. Preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings. Referring to FIG. 1, the air bubble laminat