Patent Application
20120248646
1. Field of the Invention
The present invention relates to a method and, more particularly, to a method for making a soft thin mat.
2. Description of the Related Art
A conventional mat 20 in accordance with the prior art shown in
In accordance with the present invention, there is provided a method for making a mat, comprising a first step of preparing a primary material and a secondary material, a second step of mixing the primary material and the secondary material, a third step of binding the primary material and the secondary material, a fourth step of thermosetting the primary material and the secondary material to form a molding material of a soft thin substrate layer, a fifth step of preparing and combining a cloth surface layer and a waterproof film to form a combination of the cloth surface layer and the waterproof film, a sixth step of placing the combination of the cloth surface layer and the waterproof film in a mold, a seventh step of filling the molding material of the soft thin substrate layer into the mold, and an eighth step of injection molding the molding material of the soft thin substrate layer in the mold to combine the molding material of the soft thin substrate layer with the combination of the cloth surface layer and the waterproof film so as to form a product of a mat which comprises the soft thin substrate layer, the cloth surface layer and the waterproof film.
According to the primary advantage of the present invention, the waterproof film permeates through the soft thin substrate layer during the injection molding process so that the cloth surface layer is combined with the soft thin substrate layer solidly and closely to enhance the structural strength and lifetime of the mat.
According to another advantage of the present invention, the soft thin substrate layer has a better adhesive force so that the soft thin substrate layer is attached to the surface of an object exactly and stably to provide an anti-slip function to the mat.
According to a further advantage of the present invention, the cloth surface layer has a smooth face to provide wiping and cleaning functions.
According to a further advantage of the present invention, the mat can be recycled when being worn out or broken during a long-term utilization to prevent from polluting the environment.
According to a further advantage of the present invention, the cloth surface layer has a decorative face to enhance the aesthetic quality of the mat.
Further benefits and advantages of the present invention will become apparent after a careful reading of the detailed description with appropriate reference to the accompanying drawings.
Referring to the drawings and initially to
The soft thin substrate layer 11 is made of a thermoplastic polymer. Preferably, the soft thin substrate layer 11 is made of polyurethane (PU). The soft thin substrate layer 11 has various colors by dyeing. Alternatively, the soft thin substrate layer 11 is transparent. Preferably, the soft thin substrate layer 11 has a thickness smaller than 1 mm. The waterproof film 13 is made of PU or thermoplastic polyurethane elastomer (TPU). The waterproof film 13 is sandwiched between the soft thin substrate layer 11 and the cloth surface layer 12. The cloth surface layer 12 is made of a micro-fiber. Preferably, the cloth surface layer 12 has a thickness of about 0.3 mm.
Referring to
In the first step 30 of preparing a primary material and a secondary material, the primary material is made of PU, and the secondary material is made of a composite material that hardens or solidifies the primary material. In the first step 30 of preparing a primary material and a secondary material, the primary material has various colors by dyeing. Alternatively, the primary material is transparent. In the second step 31 of mixing the primary material and the secondary material, both of the primary material and the secondary material are disposed at a liquid state. In the third step 32 of binding the primary material and the secondary material, the primary material and the secondary material bind together during a bridging reaction. In the sixth step 35 of placing the combination of the cloth surface layer 12 and the waterproof film 13 in a mold, the mold is disposed at a vacuum condition and includes an upper die and a lower die. In the seventh step 36 of filling the molding material of the soft thin substrate layer 11 into the mold, the molding material of the soft thin substrate layer 11 is poured into the mold at a low pressure.
Accordingly, the waterproof film 13 permeates through the soft thin substrate layer 11 during the injection molding process so that the cloth surface layer 12 is combined with the soft thin substrate layer 11 solidly and closely to enhance the structural strength and lifetime of the mat 10. In addition, the soft thin substrate layer 11 has a better adhesive force so that the soft thin substrate layer 11 is attached to the surface of an object exactly and stably to provide an anti-slip function to the mat 10. Further, the cloth surface layer 12 has a smooth face to provide wiping and cleaning functions. Further, the mat 10 can be recycled when being worn out or broken during a long-term utilization to prevent from polluting the environment.
Referring to
Referring to
Although the invention has been explained in relation to its preferred embodiment(s) as mentioned above, it is to be understood that many other possible modifications and variations can be made without departing from the scope of the present invention. It is, therefore, contemplated that the appended claim or claims will cover such modifications and variations that fall within the true scope of the invention.
