Patent ID: 8381495

Claim:
A method for manufacturing a gel mat comprising a hermetically sealed bag comprising two layers of a film material, wherein the bag comprises polymer gel flakes, said method comprising the following steps A to E: A) Preparing the film material: a step of cutting the film material to correspond to a desired dimension of the gel mat; B) Making the bag: a step of contacting the two layers of the film material by applying a plastic layer to the two layers of the film material and heating the plastic layer to fuse the two layers of the film material to obtain the hermetically sealed bag, except for a portion to be used as an injection port; C) Pouring a monomer solution: a step of intermixing water, a monomer, a crosslinking agent, and an initiator selected from group consisting of (i) a thermal initiator, optionally with a metallic compound, and (ii) a redox initiator, optionally with a metallic compound, to obtain a monomer solution, pouring the monomer solution into the bag through the injection port, and then closing the injection port, wherein the thermal initiator is selected from the group consisting of a peroxide compound and an azo compound; D) Heating to solidify the monomer solution: a step of placing the bag, into which the monomer solution has been poured in step C, flat on a heater and heating it to polymerize the monomer solution in the bag and generate the polymer gel flakes to produce the gel mat; and E) Inspecting and packaging the mat: a step of inspecting the obtained gel mat of steps A to D, and then packaging an inspection-passed gel mat and storing it in a warehouse.