Air pad using double weave

Abstract

The air pad according to the present invention can be used in the manufacture of a thermo-keeping and heat insulation material, an air mat, an air bed, a floating cover, etc. since double weave can have air therein which has an excellent thermo-keeping property, and the manufacturing process of the products can be simplified by the present invention.

1 . An air pad, comprising:
 an expansion part  10  which is formed of an upper woven fabric layer  11  and a lower woven fabric layer  13 , which are separable, and can be expanded by compressed air injected into a space  15  between the upper woven fabric layer  11  and the lower woven fabric layer  13 ;   a non-expansion part  20  which is continuously formed between the expansion parts  10  and formed from the expansion part  10  and formed of a single layer; and   a coating layer  40  which is formed on the expansion part  10  and the non-expansion part  20  and is provided so as to prevent the compressed air in the space  15  from being discharged to the outside,   
       wherein the expansion part  10  and the non-expansion part  20  are repeatedly formed, and the expansion part  10  is formed of a plain weave, and the non-expansion part  20  is formed of a basket weave, and the cover factor value calculated by the following formula is 2000 to 2200,
   Cover Factor(CF)=(warp density)×√{square root over ((denier of warp))}+(weft density)×√{square root over ((denier of weft))}  [Formula]
 
 warp density=number of warp/inch 
 weft density=number of weft/inch. 
 
     
     
         2 . The air pad of  claim 1 , wherein the double weave raw fabric of the air pad is formed of a polyester thread of 50 denier to 120 denier or a polypropylene thread of 100 denier to 300 denier, and a seam pattern part is not required between the expansion part  10  and the non-expansion part  20 . 
     
     
         3 . The air pad of  claim 2 , wherein the expansion part  10  and the non-expansion part  20  are made of polyester, and the coating layer  40  is made of a thermoplastic polyurethane (TPU), and the coating amount of the coating is 60 g/m 2  to 150 g/m 2 . 
     
     
         4 . The air pad of  claim 3 , wherein a polyester mesh is adhered to the coating layer  40  in order to protect the air pad. 
     
     
         5 . The air pad of  claim 2 , wherein the expansion part  10  and the non-expansion part  20  are made of polypropylene, and the coating layer  40  is made of polypropylene, and the coating amount of the coating is 140 g/m 2  to 200 g/m 2 . 
     
     
         6 . The air pad of  claim 5 , wherein a polypropylene mesh is adhered to the coating layer  40  in order to protect the air pad. 
     
     
         7 . The air pad of  claim 1 , wherein a non-expansion part  22  made of a single layer is formed at a rim of the air pad, and the non-expansion part  22  is made of a basket weave, and the expansion part  10  and the non-expansion part  20  are repeatedly formed at an inner side of the rim, and the non-expansion part  20  is formed at constant interval d, s. 
     
     
         8 . The air pad of  claim 1 , wherein the expansion part  10  is formed at the rim of the air pad, and the upper woven fabric layer  11  and the lower woven fabric layer  13  which form the expansion part  10  of the rim are adhered and sealed to each other by an adhesive  55 . 
     
     
         9 . The air pad of  claim 1 , wherein the air pad can be used in manufacturing at least one of a thermo-keeping and heat insulation material, a soundproof material, an air mat, an air bed, and a floating cover. 
     
     
         10 . The air pad of  claim 1 , wherein the double weave raw fabric formed of the expansion part and the non-expansion part is subjected to an ironing process in a state of being heated up to 70 to 100° C. before the coating layer  40  is formed. 
     
     
         11 . A method for manufacturing an air pad, the method comprising the steps of:
 (a) preparing a double weave raw fabric which includes an expansion part  10  being expanded by compressed air, and a non-expansion part  20  being continuously formed between the expansion parts  10  and being formed from the expansion part  10  and being formed of a single layer; and   (b) forming a coating layer  40  on the double weave raw fabric after the step (a), wherein the coating layer  40  is provided to prevent the compressed air in the space  15  from being discharged to the outside, and the expansion part  10  is formed of a plain weave, and the non-expansion part  20  is formed of a basket weave, and the cover factor value calculated by the following formula is 2000 to 2200,
   Cover Factor(CF)=(warp density)×√{square root over ((denier of warp))}+(weft density)×√{square root over ((denier of weft))}  [Formula]
 
 warp density=number of warp/inch 
 weft density=number of weft/inch. 
   
     
     
         12 . The method of  claim 11 , wherein (a1) a pre-heat treatment step is included between the step (a) and the step (b),
 wherein in the pre-heat treatment step, the double weave raw fabric is passed through rolls in a state of being heated up to 70° C. to 100° C., thus ironing the double weave raw fabric.   
     
     
         13 . The method of  claim 11 , wherein a non-expansion part  22  formed of a single layer is formed at a rim of the double weave raw fabric, and the non-expansion part  22  is formed of a basket weave, and the expansion part  10  and the non-expansion part  20  are repeatedly formed at an inner side of the rim, and the non-expansion part  20  is formed at constant interval d, s. 
     
     
         14 . The method of  claim 11 , wherein an expansion part  10  is formed at a rim of the double weave raw fabric, and the upper woven fabric layer  11  and the lower woven fabric layer  13  which form the expansion part  10  of the rim are adhered and sealed to each other by the adhesive  55 .