Patent ID: 7807095

Claim:
A method for manufacturing an air mat formed in such a manner as to integrally couple a cushion part having a plurality of air bags arranged therein for containing air insides thereof with a plate-shaped lower sheet disposed on the lower surface of the cushion part, the method comprising the steps of: preparing a lower mold having a plurality of air bag molding recesses having given depths and arranged at given intervals thereon, and having a cut groove having a given depth formed on a partition between the adjacent air bag molding recesses, for molding the cushion part of the air mat, preparing a plate-shaped upper mold adapted to be coupled with the lower mold, and preparing the plate-shaped lower sheet; mounting a plurality of communicating members detachably to the cut grooves, for making the plurality of air bag molding recesses of the lower mold communicate with each other, each of the plurality of communicating members having a communicating hole passed through both end portions thereof and having a length larger than the thickness of each of the partitions of the lower mold, such that when mounted at the cut groove, the both end portions of the communicating members are disposed within the adjacent air bag molding recesses; pouring a resin composite material into the plurality of air bag molding recesses in the lower mold; coupling the plate-shaped lower sheet with the top surface of the lower mold, for covering the entrances of the plurality of air bag molding recesses; disposing the upper mold on the top surface of the lower sheet, for coupling lower mold and the upper mold with each other; and rotating the upper and lower molds coupled with each other by means of a rotational molding machine such that the resin composite material is coated on the inner surfaces of the plurality of air bag molding recesses and at the same time the cushion part is formed integrally with the lower sheet.