Method for manufacturing pad with dynamic massage bubbles

A method for manufacturing a pad with dynamic massage bubbles, comprising steps of:

• Step 1:
• preparing an upper-half foam substrate and a lower-half foam substrate to be stacked vertically;
• Step 2:
• intercalating a separating portion between the upper-half foam substrate and the lower-half foam substrate that are aligned vertically, wherein the separating portion includes two or more separately located bubble-forming segments and an air passage segment connected between the adjacent bubble-forming segments, in which the air passage segment has a width smaller than a width of each of the bubble-forming segments;
• Step 3:
• stacking the upper-half foam substrate and the lower-half foam substrate after performing Step 2 vertically in a mold for hot press bonding, wherein during the hot press bonding, the upper-half foam substrate and the lower-half foam substrate are not bonded at any part thereof where the separating portion is present, and air existing in space between the upper-half foam substrate and the lower-half foam substrate absent the separating portion is forced into the separating portion, until the upper-half foam substrate and the lower-half foam substrate are bonded wherever the separating portion is absent, and the separating portion containing the air inflates under heat, so that between the upper-half foam substrate and the lower-half foam substrate, air bubbles form at least in the bubble-forming segments to cause an upper surface of the upper-half foam substrate and a lower surface of the lower-half foam substrate to bulge outward so that the massage bubbles are formed from the air bubbles, and the air passage segment forms an air passage, thereby obtaining a pad intermediate;
• Step 4:
• transmitting the pad intermediate obtained in Step 3 to an oven for form-setting bake under a progressively decreasing baking temperature, wherein as the pad intermediate is baked to shrink, a volume where the air bubbles are present reduces, so that an air pressure in each of the air bubbles increases;
• and an initial value of the baking temperature in the oven is lower than a temperature for the hot press bonding in the mold;
• Step 5:
• removing a resulting pad product from the oven.