US20080088085A1

US20080088085A1 - Method for manufacturing a foam game panel and structure using the same

Info

Publication number: US20080088085A1
Application number: US11/582,732
Authority: US
Inventors: Kun-Yu Hsu
Original assignee: Shine Sport Facility Co Ltd
Current assignee: Shine Sport Facility Co Ltd
Priority date: 2006-10-17
Filing date: 2006-10-17
Publication date: 2008-04-17

Abstract

The present invention discloses a method for manufacturing a foam game panel and structure using the same. The method includes the steps of selecting a fabric while designing a pattern on a moldboard, constructing a foam material on a groove hole of the moldboard, such that the foam material is constructed on a surface of the fabric and along the grove hole to define a design pattern, and then producing a foam pleat on a surface of the fabric by expanding, hardening and shaping the foam material in an oxidizing process. The foam game panel structure of the invention is used to replace the traditional method and structure that uses stitching or plastic mold template, and thus the invention achieves the effect of saving the cost of the mold, providing a fast manufacture, and giving a variable safe stylish design with an artistic appearance.

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention
The present invention relates to a method for manufacturing a foam game panel and a structure manufactured by the method, and more particularly to a method for manufacturing a foam game panel and a structure made by constructing a foam material on a moldboard and attaching the foam material on a fabric, so that patterns and arc embossments are formed on the surface of the fabric and provided for playing a game or serving as a decoration.
2. Description of the Related Art
Games can help relaxing our tension and releasing our pressure, and we can learn the knowledge and skills and also can have physical training or fun during the process of playing a game. A game can be played with or without tools or accessories. In other words, a game can be played by people only, or by means of various different game materials and equipments to give more fun. In different games, a game panel is a lightweight, foldable and portable game medium provided and used for a balancing game. The game panel is mainly composed of a fabric and a design pattern, and the size and shape of the fabric varies with the number of players, and the design pattern is attached directly onto the fabric. Particularly, the design pattern is protruded slightly from the surface of the fabric to give a three-dimensional pattern, such that one person or two persons or more can hold the edges of the fabric during the game, and a rolling ball can be rolled on the surface of the fabric with a design pattern and rolled to a destination or a score point along an internal path of the design pattern. The game panel can train the balance of hands and eyes of a player, and also can provide lots of fun to the players.
To attach the design pattern with the fabric to produce a slight protrusion, two main traditional manufacturing methods are used. In the first traditional method, the game panel includes a fabric and a plurality of strip elements, which are mainly cloth strips and each strip element is sewed and fixed onto the fabric, so that the strip elements can be protruded slightly on the surface of the fabric to give a three-dimensional form. With the arrangement and combination of the strip elements, a design pattern is formed. Further, a rolling ball is provided for players to play a balancing game, and the rolling ball can move along the path among the strip elements to achieve the balance and objective of the game.
However, the foregoing manufacturing method requires cutting the strip elements in appropriate length and size, and then sewing and fixing the strip elements onto the fabric, and the whole process is complicated. Furthermore, it is necessary to inspect the manufactured strip elements and trim extra threads on the front and back sides of the fabric to give an artistic look and prevent the threads from becoming loosened or separated. Therefore, such manufacturing method consumes much time and efforts, and the sewed strip elements usually do not have a three-dimensional layout.
In the second traditional method, the game panel is made by attaching and fixing a plastic pattern that is produced by a mold onto the fabric. Although this method can simplify the aforementioned sewing process, the cost for the mold of the plastic pattern is high, and the effect of attaching the plastic pattern onto the fabric is not as good as expected. Since the plastic pattern comes with specific thickness and hardness, the game panel cannot be folded and storage easily. As a result, the game panel occupies much space.
In view of the foregoing shortcomings of the prior art, the inventor of the present invention based on years of experience on the design and manufacture of game panels to conduct experiments and modifications, and finally developed a game panel in accordance with the present invention to overcome the foregoing shortcomings.

SUMMARY OF THE INVENTION

Therefore, it is a primary objective of the present invention to overcome the shortcomings of the prior art by providing a method for manufacturing a foam game panel, and the method constructs a foam material at a groove hole of a moldboard, so that the foam material is constructed on a surface of the fabric and along the groove hole, and a three-dimensional pattern is produced after the foam material is oxidized. The invention can be used to substitute the processes of sewing cloth strips or attaching a plastic mold, and thus the invention can simplify the manufacturing procedure and save the manufacturing time.
Another objective of the present invention is to provide a foam game panel structure, wherein a design pattern is formed by attaching a foam material onto a fabric, and an arc protruding surface is produced after the foam material is oxidized, so as to provide a three-dimensional layout and a slippery-resisting effect.
To achieve the foregoing objective, the method of manufacturing a foam game panel in accordance with the present invention comprises the steps of:
a. selecting a fabric;
b. designing a pattern on a moldboard, such that the pattern disposed on the moldboard defines a groove hole;
c. constructing a foam material at the groove hole of the moldboard, so that the foam material constitutes a pattern disposed on a surface of the fabric and constructed along the groove hole; and
d. removing the moldboard and shaping the foam material by an oxidizing process.
The foam game panel structure of the present invention comprises:
a fabric, having a flexible surface; and
a foam pleat, made of a foam material, for forming a design pattern by attaching the foam material on the fabric, and producing a foam pleat by expanding, hardening and shaping the foam material in an oxidizing process, such that the foam pleat has a three-dimensional form.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic manufacturing flow of a method in accordance with the present invention;

FIG. 2 is a schematic perspective front view of a first preferred embodiment of the present invention;

FIG. 3 is a schematic rear view of a first preferred embodiment of the present invention;

FIG. 4 is a side view of a structure in accordance with a second preferred embodiment of the present invention; and

FIG. 5 is a schematic view of a structure in accordance with a third preferred embodiment of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The objectives, shape, structure, apparatus, characteristics and effects will become apparent by the detail description together with the accompanying drawings. Of course, some of the elements of the present invention may be substituted by their equivalents, and the detailed description of preferred embodiments given in the specification illustrates the structure of the invention.
Referring to FIG. 1 for a method for manufacturing a foam game panel in accordance with a preferred embodiment of the present invention, the manufacturing method selects a fabric 11, and the size, shape and color of the fabric 11 can be cut or designed according to customer requirements, and the material of the fabric 11 can be a woven cloth, an unwoven cloth or any other appropriate material, and then a design pattern 12 is used as a pattern fixed onto the fabric 11, and the design pattern 12 can have lines, stylish shapes or characters. Particularly, the design pattern 12 is designed on the moldboard 13 and in a hollow form, and the design pattern 12 of this embodiment is in the pattern of a maze.
Further, a foam material 14 is applied and constructed on the groove hole 15 of the moldboard 13, and the concentration and color of the foam material 14 can be adjusted as needed, and the foam material 14, and the concentration of the foam material 14 adjusted according to different composing materials can determine the thickness of lines formed after the foam is hardened. For instance, a high-concentration foam occupies a smaller space and gives thinner lines, and a low-concentration foam occupies a larger space and gives thicker lines. The color of the foam material 14 can match with the color of the fabric 11 to enhance the artistic look and design. Further, the foam material 14 can be one selected from the collection of polyurethane (PU), ethylene vinyl acetate (EVA), polypropylene (PP), polyethylene (PE) and their mixture, such that the foam material 14 can be coated or injected onto an object and shaped after being oxidized.
By stacking the moldboard 13 having the design pattern 12 onto the surface of the fabric 11 and constructing the foam material 14 into the groove hole 15 of the moldboard 13, we can produce a pattern on the surface of the fabric by applying the foam material 14 along the groove hole 15. Finally, the moldboard 13 is removed, and the foam material 14 is oxidized. The foam material 14 is shaped into a three-dimensional pattern with specific height and curvature, after the foam material is expanded and hardened for approximately 60 seconds, and thus the required manufacturing time is short. In the process of expanding and hardening the foam material 14, curved pleats are produced at the positions where the foam material 14 is attached. In other words, recessions are formed on another surface of the fabric 11, such that after the fabric 11 is turned over, the recessed pattern of the fabric 11 can be used for playing a different game.
The manufacturing procedure of the present invention can replace traditional manufacturing methods to reduce the manufacturing time, procedure and manpower. Furthermore, the foam material 14 is combined with the fabric 11 naturally after the foam material is expanded, and thus the foam material will not fall off easily and also can provide waterproof and slippery-resisting effects.
Referring to FIG. 2 for a structure of a foam game panel 2 in accordance with a first preferred embodiment of the present invention, the foam game panel 2 comprises a fabric 21 and a foam pleat 22, wherein the fabric 21 has a flexible surface, and the size or color of the fabric 21 is set according to customer requirements, and the material of the fabric 21 can be a woven cloth, an unwoven cloth, or any other appropriate material, and the foam pleat 22 is made of the foam material. In the manufacturing method of this embodiment, the foam material is constructed into the groove hole of the moldboard, such that the foam material is attached onto the surface of the fabric 21 and along the groove hole, and then the foam material is shaped and fixed onto the fabric 21 by an oxidizing process to form a three-dimensional foam pleat 22. The foam material can be polyurethane (PU), ethylene vinyl acetate (EVA), polypropylene (PP), polyethylene (PE), a mixture of the foregoing materials or any other appropriate foam material.
In this embodiment, the design pattern 23 is in the pattern of a maze, and the fabric 21 has a plurality of score holes 24 disposed at appropriate positions of the fabric 21, and each score hole 24 has a number 25 around the score hole 24 that serves as a basis for scoring points. Each score hole 24 further includes a woven net 26 fixed onto another surface of the fabric 21, so that an object passing through the score hole 24 can be caught by the woven net 26.
If the front side of the foam game panel 2 of the invention is used for playing a game, at least one player holds the edges of the foam game panel 2, and places a rolling ball 28 on the surface of the foam game panel 2. The player controls the inclination and direction of the foam game panel 2 to roll the rolling ball 28 along a path in the design pattern 23. If the rolling ball 28 reaches and falls into a score hole 24, then the player scores points according to the number 25 marked next to the score hole 24.
Referring to FIG. 3, the foam pleat 22 produces a groove 27 at a corresponding position on the surface of the fabric 21, after the foam material is shaped to form the foam pleat 22, and the groove 27 is sunken into the surface of the fabric 21 for allowing a ball to roll in the groove 27 for playing various different kinds of games, such as a balancing game by rolling the ball in the groove 27.
Referring to FIG. 4 for a second preferred embodiment of the present invention, the surface of the foam game panel 2 having the foam pleat 22 faces down and contacts the floor, and the friction produced between the foam pleat 22 and the floor provides the slippery-resisting effect and the foam game panel 2 can serve as a slippery-resisting mat.
Referring to FIG. 5 for a third preferred embodiment of the present invention, the foam game panel 3 comprises a fabric 31 and a foam pleat 32 attached and fixed onto the fabric 31, and the foam pleat 32 forms a design pattern 33, and the design pattern 33 could be a pattern of animals, plants, sceneries, geometric shapes, decorative designs or characters to match with different colors of the foam pleat 32 and fabric 31, so as to provide an artistic three-dimensional foam game panel 3 for the decoration purpose.
However, the foregoing embodiments are provided for the illustration of the present invention and not intended to limit the structure, size, and playing method of the present invention, and any ordinary person skilled in the art can make appropriate changes and modifications without departing from the scope and spirit of the invention set forth in the claims.
In view of the description above, the present invention has the following advantages:
1. The invention can save time and effort, and it can replace traditional manufacturing methods and structures to achieve the purpose of saving time and manpower.
2. The invention provides stylish designs with different colors to match with the color and pattern of the different colored foam materials and gives diversified changes to the design, and the shaped foam material has a three-dimensional artistic pattern that can stimulate consumers' purchasing desire.
3. The invention provides extensive applications, and the structure manufactured by the method of the present invention comes with an artistic pattern, and a slippery-resisting effect and also covers a wide range of applications for games or decorations.
In summation of the above description, the present invention definitely achieves the expected objective and provides an improved method and structure to enhance the performance over the prior art. The invention further complies with the patent application requirements and is duly filed for the patent application.

Claims

1. A method for manufacturing a foam game panel, comprising the steps of:

a. selecting a fabric;

b. designing a pattern on a moldboard, such that said pattern disposed on said moldboard defines a groove hole;

c. constructing a foam material at said groove hole of said moldboard, such that said foam material constitutes a pattern disposed on a surface of said fabric and constructed along said groove hole; and

d. removing said moldboard and shaping said foam material by an oxidizing process.

2. The method for manufacturing a foam game panel of claim 1, wherein said foam material is one selected from the collection of polyurethane (PU), ethylene vinyl acetate (EVA), polypropylene (PP), polyethylene (PE) and their mixture.

3. The method for manufacturing a foam game panel of claim 1, wherein said foam material produces a pleat at a position where said fabric is attached after said foam material is expanded and hardened, and a recession on another surface of said fabric.

4. A foam game panel structure, comprising:

a fabric, having a flexible surface; and

a foam pleat, made of a foam material, for forming a design pattern by attaching said foam material on said fabric, and producing a foam pleat by expanding, hardening and shaping said foam material in an oxidizing process, such that said foam pleat has a three-dimensional form.

5. The foam game panel structure of claim 4, wherein said foam material is one selected from the collection of polyurethane (PU), ethylene vinyl acetate (EVA), polypropylene (PP), polyethylene (PE) and their mixture.

6. The foam game panel structure of claim 4, further comprising a groove disposed on a surface and at a corresponding to said fabric fixed with said foam pleat.

7. The foam game panel structure of claim 4, wherein said fabric has a plurality of score holes disposed at appropriate positions for passing an object.

8. The foam game panel structure of claim 7, wherein said score hole has a number disposed at the surrounding of said score hole.

9. The foam game panel structure of claim 7, wherein said score hole has a woven net disposed around said score hole.