GB2251255A - Mat consisting of fused filament loop aggregations - Google Patents

Abstract

A mat comprises a substantially uniform thickness aggregation of irregularily shaped filament loops lying against each other so as to be substantially upright when the plane of the mat is horizontal, the loops in the surface of the aggregation being bent and fused to one another. The loops may be coated with a plastisol made of the same material as the filament. It may be used as a door or floor mat or as an artificial surface for skiing. <IMAGE>

Description

MAT CONSISTING OF FILAMENT LOOP AGGREGATIONS BacKground of the Invent on: This Invention relates to coarse net-like resilient mat made by entanglement of synthetic resin monofilaments ano more particularly to a mat consisting of filament loop aggregations and acactec for use as a porch mat of fixea dimensions or a floor mat formed and laid in a long sheet.

Instead of a conventional carpet mat or synthetic resin mat, there has been proposed a three-dimensional net-like mat consisting of synthetic resin monofilaments of high water permeability and quick dryability. Due to characteristies sucn as resiliency and weather-Droofness, such a threedimensional net-like mat may be used ,n many indoor ana outdoor fields, ana can be apolied particularly to such water using place as, for example, an inlet ana outlet of a oath room or a pool side and is apprediciated decause it is simple to wash and dry.

Also, as this kind of three-dimesnional mat is open in structure, sand and gravel brought in when it is trodden on will droD down ana will not remain on the surface. As water or the like also will orop down, the surface can be always kept dry. It is thus conventent.

In addition, when sucn eiastic sheet as a svntnetic resin sheet, foam sheet or rubber sheet is pasted to tne lower surface of such mat, the cushioning property of a mat will oe increased, the sand and water dropping from tne surface will be receiveo by this sheet pasteo to tne lower surface and the floor will de Dreventea from veins maoe dirtv directly by the dropping sand the like.

Description of the Prior Art: As disclosed in Japanese batent bublication No.

14347/1977. such three-dimensional net-like mat is formeo as a non-woven fabric wherein many monofilaments maoe of a thermoolastic synthetic resin are fused at their contact points and cooled to be soindified.

The formation of upright toots disclosed .n japanese patent publication No. 31222/1980 and Japanese patent laio open No. 85061/1987 is known as a web forming means of the above mentioned filaments in such non-woven fabric.

now. in the non-woven fabric formation ov tne above described conventional means, r,he resiliency of the individual filament bart itself is low. The filaments by this oroducing means overlap on each other compressing the filaments and, as a result, as the entangled density of tne filaments becomes nigher,the resiliency of the sneet will be lost.

On the other hand, when the web formation is made 1000- like the resiliency of the filament itself in each 1000-like the resiliency of the filament itself in each loop-like part will be developed but. in the web made of arcuate 1000ps arranged ifl a substantially fixed form, the respective loops are fuseo at their intersecting points and there are tew contact points between the adjacent loops, and therefore low resilience apsinst treadine, Summary of the Invention:: According to the present invention there ;s provide mat consisting of filament loop aggregations wherein irreguiarly formea loops are formed by wirding filaments In a coil-like fashion such tnat each of the ends of the @ boos formed by said filaments bend and are fused and bonded onto a neighbouring loop.

Description of the Drawings: The many advantages and features of the Dresent invention can be best understood and appreciated by reference to the accompanying drawings wherein: Fig. 1 is a side view snowlng principal features of embodiment of an apparatus or use i@ obtaining a mat of the present igvention: Fig. 2 is an explanatory view showing filament loops of the present invention forming in the apparatus of Fig.

Fig. 3 is a side view showing principal features of another embodiment of apparatus for use in obtaining the mat of the present invention: Fig. 4 is a side view snowing respective examples of a mat of the present invention; Fig. 5 is a step by step @iagram showing a method for producing a mat of the present igvention: ana Fig. 6 is a sioe view showing another emoodiment of mat produced bv the Dresent invention.

Detailed Descridtion of the Invention: According to the present invention there is provides a mat consisting of upright entangled loops of synthetio resin filaments in three-dimensional aggregations. having manv spaces within it to develop a cushioning property. A mat consisting of loops of various sizes debending on the object of the use can oe orovided.

In order to form such a mat, several not filaments of thermoplastic synthetic resin are Pressed and extruded through T-die orifices ana are made to fall toward a water surface.

A pair of incluned paneis are set as opposed to eacn other on the water surface and a bundle of tne above mentioned filaments 18 lowered so as to drop between these panels.

The falling hot filaments are heated by such heat sources as ceramic far infrared ray heaters so as not to be cooled by the atmosphere ana the inclined parts above water of tne above mentioned panels act to Drevent the temperature drop of the filaments by the radiation heat reflection.

Such hot filaments are easy to make into coiled loops on the water surface. Uniess the filaments are hot. the loops will be come large. Further, ,n the filaments of a reduced temperature. no coiled loop will be formed but only a bent form will be above to be made.

The height from the d,e mouth end to the water surface is 5 to 100 cm and the heat reduction of the filaments is prevented by making the die mouth end approach the water surface as much as possible.

The orifice diameter of the T-die is 0.3 to 1.5 mm as an element determining tne filament diameter, retains the resiliency and durability of the formed filaments and prevents tne permanent set.

A mat sheet consisting of filament aggregations of respective widths can be made by arranging the numbers of orifices corresponding to the widths of 90, 120 and 150 cm of intended mat sheets with an orifice arrangement of a T-die of 3 to 6 longitudinal rows at the intervals of 3 to 5 mm ana a pitch of 3 to 5 mm in the lateral row.

That 1S to say, a hot filament bundle extruded out of the die of such orifice arranqement is made to fall vertically toward cooling water and is received by submerged rollers rotating at a speed sufficiently slower than the falling speed to limit the falling sDeed in water and to give the f filaments a resistance toward the water surface from the above mentioned rolls.Loops having a peripheral length of a filament length corresponding to the difference between the extruding speed of the respective filaments and the falling speed in water will be sequentially contInuously formed to De coil-like on the water surface by this reststance.

At this time. in order to make it easy to form loops ana to make bent irregular loops, it is effective to keep botling the cooling water surface between the inclined panels.

This boiling state vibrates the respective filaments wound on the water surface. As a result, entangled disarranged coiled loops are induced on the water surface.

In order to make the boiling state on the water surface between the inclined guise panels, it is important to Keep the filaments coming out of the die at a high temperature until the liquid level. Generally, when the filaments are in contact with the atmosDhere, the filament temperature will quickly reduce. The water surface heated by the falling in water of the filaments bundle kept at a filament extruding molding temperature of 200 to 150 C by the above mentioned neating treatment to Drevent a.r cooling in the filament coming out of the de will be in the boiling state.

Therefore, when the cooling water is keot at a high temperature of 60 to 80 C. this boiling will be maintainea.

When the filaments are molded to be coiled loops while kept at a high temperature, the fusing Detween the loops will be accelerated. Further, when tne cooling water is at a high temperature, when the molded loops are pulled out into the atmosphere by the guide rolls ano are sent to the secondary process, they will be able to be easily dried with cool or hot air.

A filament loop aggregation has its coil density decreased by increasing the rotation (pulling speed in water) of the rolls in water and has its coil density increased by reducing the pulling sDeed.

By the way, in order to strengthen the filament fusing between the coil and loop and strengthen the durability of the coil itself, it is effective to coat the aggregat70ns with a bonding agent. Thereby, the entire filament loop aggregations can be strengthened and it is effective to Drevent the permanent set of the upright coil part.

A vinyl olastisol is generally used for the bonding agent In this case. The strength and durability of the mat can be increased by adopting a vinyl plastisol adapted to the materials of the mat and sheet.

It is effective to use a Dlastsol of the same material mixture as of the filaments for the bonding agent. The bonding $agent reduced in the viscosity by adding 20 to 30% plasticizer to the filament material is sDrayed or painted or has the above mentioned aggregation dipped in its liquis bath, has then the excess plastisol removed with rollers, is then heated at 170 to 150 C with a dryer to be melted and iS bonded to the filament surfaces of the aggregation to increase the fusion between the filaments.

By the way, a vinvl plastisol is made by adding a plasticizer and various stabilizers to a powdery vinyl can be used for the above mentioned obJect.

On the other hand, even if the thickness width of tne hanging filament bundle is not requlated. a three-dimensional formation of a coiled loop will be able to be made. @owever.

the size of the loop formed on the liquid surface is not fixed. Therefore. a means of regulating the thickness width of the filament bundle functions effectively to make uniform coiled three-dimensional aggregations of an intended thickness.

The entire inclined panel is of stainless steel plate or the part exposed above the cool inc water surface may be of a stainless steel plate and the part .n the cooling water mav be of a stainless steel screen plate. It Is effective that the Dane; angle on the water surface is neld to be 45 to 80 degrees in order to reflect tne radiation heat from the heat source and to slide 7nto water the filaments having fallen onto the panel surface.

It is effective to keep the temperature of the inclined panel at 100 to 130 C.

By adjusting the opposed clearances of a pair of oDDosed inclined panels and rolls in water, various modified aggregations of a coiled loop three-dimensional structure can be continuously molded.

Rotary rollers exDosed in a Dart of the peripheral surface on the water surface can be applied instead of such inclined panels. However. ln this case. the radiation heat reflecting action will be so little as to require a heat source to coDe With it.

In molding synthetic resins, the general temperature as of the cooling bath is about 50 C for PE (polyethylene) ana PP (polypropylene). about 10 to 40 C for PVC (polyyinyl chloride) and about 85 C for PS (polystyrene).

The surface tension of water on PVC (polyyanyl chloride) is so high as to be about 60 to 70 dynes./cm. that fine filaments of an outside diameter less than imm Will pe overlapped in turn above the water surface. the coiled loops formed here will be bonded In several steps ana Will be cooled in water and therefore the object aggregations coarse in the loop clearances will not be obtained. Therefore. @ order to sequentially sink the colled loops on tre liduig surface. it is effective to add a surface active agent reducing the surface tension of the cooling bath.

Embodiments: Fig. 1 is a side v7ew showing component Darts in an optimum apparatus for preparing a mat of tne present invention. Four filaments 2 are to fall vertically toward cooling water 5 from a T-die 1 extruding a thermophastic svnthetic resin material under pressure.

In the lateral direction (front to back direction on tne paper surface) of the T-die in this case. man filaments 2 are to be molded as arranged at predeterminged intervals (pitch of 3 to 5 mm) in the length zone corresponding to the lateral w7dth of an intended molding.

In the falling zone of these filaments 2, bar-lQke ceramic far 7nfrared ray heaters 3 are arranged on both sides of the filament bundle so as to be heating heat sources.

Laterally long inclined panels 4 are arranged respectively below tnese heaters 3.

The above mentioned inclined panel 4 consists of an upper piece 4a of a horizontal angle s set in the range of 45 to 80 degrees and a lower piece 4b submerged below the water surface of the cooling water 5. The lower pieces 4b are arranged so as to nold the above mentioned filament bundle from both sides and the panels 4 are formed so as to be adjustably movable toward the center of the filament bundle from both s7des.

As a result. the filament bundle will be limited n the thickness width by the above mentioned panels 6 in the zone reaching the water surface of the cooling water 5, further the outside filaments 2 of the bundle will fail onto the upper parts 4a of the panels 4, Will slide on the upper parts 4a and will be submerged into the cooling water 5.

Further. submerged rollers 6 formed movably in the direction of the above menthjoned thickness Width as operatively connected with the above mentioned panels 4 are arranged In the cooling water 5, have many engaging Dins @ for stopping sliding erected on the peripheral surfaces of the rollers 6, periodically rotate sn the winding direction indicated by the arrow In the same drawing and are controlles In the rotating speed to be lower than the falling speed of the above mentioned filaments 2.

Therefore, as the respective filaments 2 falling from the die 1 at a high speed are reduced in the sinking speed water by the above mentioned submerged rollers 8. they will be relaxed by the lament length corresponding to tne difference between the falling speed and sinking speed.

These reiaxations will concentrate in the water surface zone due to the buoyancy of the filaments 2 of a small specifie gravity: As a result, the filaments 2 will form loops on the water surface.

This state Is shown sn Fig. 2. That Is to say. the fIlaments 2 extruded out of the die will reach the water surface of the cooling water 5 while being kept near the temperature at the time of molding by heating by the above mentioned heaters 3 in the falling zone in aer and by the reflected heat from the upper Darts 4a of the inclined panels 4. Teh filaments 2 having sunk in the colling water 5 will quickly lower in temperature and will be hardened. However.

these hardened filaments 2 will be regulated in the pulling amounts by the submerged rollers 6 stoDDed In sliding by the engaging pins 7, therefore the hardened parts 7n water will be subjected to resistances from the submerged rollers 6 and thereby the soft filaments 2 still at a high temperature just before reaching the water surface will be curved and will be gradually pulled into water while describing loops to form coiled loops.

When the temperature within the bath of this cooling water 5 is kept at 60 to 80 C. the coolang water 5 between the above mentioned inclined caneis 4 will pe locally boiled by heating by the f7laments 2 reaching the water surface while at a high temperature. By this boiling. the water surface of that part will be waved and greatly rocked and therefore the filaments 2 describing loops on this water surface will be waved and disarranged in response to the rocking of the water surface.

Therefore. the total surface contact will be obstructed by the concavo-convexes by this disarrangement between the adjacent loops of the disarranged forms overlapped on the water surface and the contact point parts will be comparatively many.

In such contact part loops will be fused with each other and will be cooled to be hardened. Therefore, colled loops naving comparatively many fused Darts between the adjacent loops will be continuously formed In turn and a mat sheet (See Fig. 4(a)) consisting of a filament loop aggresation A in which coiled loops a, are cross-linked longitudinaily and laterally with loop edges overlapping between adjacent filaments 2 will be formed.

As understandaole from the structure of the aoove mentioned illustrated aggregation A. In the aggregation A in which the respective loops are formed porizontally at the time of the above mentioned wording, the above mentioned respective loops will rise 7n the upright direction when the continuous body Is used as horizontally placed.

On the other hand, as showing the above mentionec Fig.

2, the outside filaments 2 hardened on the upper part 4a of the panel 4 by the filament bundle fazing on the nc@@ed panel 4, wil describe loops on the slope of the part 4a, will be heaped up, will therefore slip down Into the @@eling water 5 along the above mentioned part 4a while the adjacent loops are substantia 1 , close to the total surface contact and will be . hardened.Therefore, as shown n tne same drawing, these filament parts will become layers of a hign filament density consisting of a loop ovrection at right angles with the above described coiled loop a. by the other center part filaments 2 and will be fused with eacn other on the contact surface of the coiled loop a,.

Therefore, as shown in Fig. 4(b), the filament loop aggregation A will become an aggregation of the above mentioned layer consisting of a loop a2 fused to one side of colled loop a,.

When the movement of the above mentioned inclined panel 4 Is adjusted and the above mentioned laterally fallen loop a2 is formed for several filaments outside the filaments 2.

an aggegation A (see Fig. 4(c)) consisting of the laterally fallen 1 boos a2 of thick layers will be formea and. when the Danels 1 are both moved and the above mentioned laterally fallen loops a2 are made for both outside filaments 2 of the filament bundle, an aggregation A (See Fig. 4(d)) in wn,cn layers of the laterallv fallen loops a2 are formed on both front and back sides holding the coiled loop al will be formed an aggregation A (see Fig. 4(eì) in which the entire filament bundle is made layers of laterally fallen loops a2 be able to be formed.

By the way, the formation of such various aggregations A is determined bv the corresponding positions of the bundle of the filaments 2 falling as arranged from the die 4 and of the inclined panels 4, it is theoretically possible to use a T-die different in the filament extruding spacing (nozzle pitch spacing) for fixed guide panels besides the above described operation o moving the above mentioned panels Fig. 3 18 a side view of another example of the apparatus obtaining a mat of the present Invention. instead of the inclined panels 4 in the above mentioned example. a pair or water contacting rolls 8 exposed by about 10 to 20% of the diameter above the water surface may be provided rotatably and laterally movable. The other parts similar t the respective parts of the above mentioned embodiment Shat bear respectively the same reference numerals. W represents a reflecting plate.

According to this example. the thickness Wicth of tne filaments 2 falling from the die 1 is regulates by these rolls 8. When these rolls 8 move toward the flament bundle.

the outside filament 2 will fall onto the peripneral surface of the roll exposed above the water surface to form a laver of the above described laterally fallen loops a. be aver Dart will be pulled into tne cooling water 5 by tne above mentioned rolls 8 while rotating by the action of pulling it into the loop filaments by the submerged rollers 6.

The same as in the above mentioned example. various aggregations A in Figs. 4(a) and 4(e) can pe formed by regulating the positions of the rolls 8 for the filament bundle.

By the way. in order to Dull the cooled loops formed or the cooling water surface into water without disturbing their form, a surface active agent is added into cooling water 4.

Amounts of addition of surface active agents per 100 parts of water: Anionic system: Alkylbenzenesulfonate: 1 to 0.2 part.

Dialkylsulfocuccinate: 1 to 0.5 part.

Nonionic system: Polyoxyethy'ene nonylphenyl ether: 1 to 0.1 part.

It is effective to add 0.05 to 0.2% dialkylsulfosuccinate which is high in the capacity of reducing the surface tension and In the connecting effect With a slight amount.

Now, in this kind of apparatus. in order to keep the cooling bath level constant, cooling water is circu'ated with a pump while being overflowed. In such case, many bubbles will be generated in an auxiliary tank level detecting electrode and cooling bath and will be disadvantageous in molding. In this respect, at the above mentioned effective component concentration of the dialkylsulfosucoinate. many bubbles tend to be generated. Therefore, it can be said to be optimum to add and use Dreferablv 0.5 to o.2% dialkylsulfosuccinate.

The thus formed filament loop aggregation A may be coated with a plastisol made of the same material mixture as of the filament to Drevent the bonding strength reduction and permanent set of the filament loops.

The apparatus formation therefor is shown in Fig. 5.

An aggregation A pulled up from a bath 10 of the above mentioned cooling water 5 is fed into a primary dryer 12 b a feeding roller and is dried at a low temperature. In this drying. the aggregation A is still about 70 C by the cooling water 5 at a high temperature. Therefore, the water can be comparatively easily and positively removed by blowing warm wnd or the like.

The dryer aggregation A is fed into a surface coating process part 13 by the above mentioned plastisol, 7S Drocessed in the part 13 by such means as blowing, painting or dipping. Is then fused by high temperature drving in a secondary dryer 14 and is wound up on a winder 15. As shown in Fig. 6, a back sheet B consisting of a resin sheet, foamed sheet, resin net-sheet or rubber sheet etc. may be useo as bonded to the back surface of the aggregation A ln repose t the object of use of the mat or sheet.

(Formation Example 1) Polyvinyl chloride PVC (P-1300 100 parts plastioizer DPO Dioctyl phthalate Stabilizer Dibutyl tin laurate Cadmium stearate O.o part Barium stearate 0.4 part Colouring agent 0.1 Dart A compound material of the above mentioned mixture is molded to be filaments by an extruding molder.

The clearance between the inclined panels on the cooling water surface is set at 15 mm. The filament molding orfice diameter of the d7e is made 0.8 mm. The T-d7e orifice arrangement is of four longitudinal rows at the intervals of 4 mm and a lateral orifice pitch of 5 mm.

The clearance between the T-die and cooling water wurface is 5 cm. The die temperature is 185 C. The die pressure is 19 kg/cm. The extruding pressure is 190 kg/cm.

The cooling water temperature is 60 to 80 C. The guide panel temperature is 120C. Two ceramic far infrared ray heaters of 2.5 KW each are used. At a molding linear speed of 2m per minute, loops at a sDeed of 40 cm per minute can be made.

In tis formation. by only holding the filament bundle in its thickness width directIon with the inclined panels, the front and back surfaces of the aggregations can be maae uniform. The aggregation shown in Fig. 4(a) is obtained and is made a product through Crying and bonding steps.

As the extruder die Dressure is applied and hot filaments are extruded into air, the finished dimension of the filament is 0.2 mm thicker than the filament orifice of a diameter of 0.8 mm of the die and a filament coil structure of a diameter of 1 mm is made. Even if the clearance between the inclined panels is set to be 15 mm, tie aggregation molded under the width regulation by this clearance wil shrink when the filament is hardened and will be therefore 13.5 to 14 mm thick. The loop diameter is about 7 mm.

Under the above mentioned setting, when one of te inclined panels and water rollers is moved by 2 mm toward the center part of the filament bundle, the aggregation form shown in the above mentioned Fig. 4(b) will be formed. When it is further moved by 2 mm in addition, the aggregation form shown in Fig. 4(c) will be formed.

The aggregation in Fig. 4(b) is higher in the adhesion to the floor as a mat or sheet than the aggregation n Pig.

4 (a), can be 1 ncreased in the strength by the laterally fallen direction loops in the aggregation, is high n cushioning and is effective.

In the mat sheet consisting of the aggregations in Fig.

4(c), as the lateral direction coil is double, the mat strength can be further increased but the cushioning sropert is lower than of the aggregation in Fig. 4(b).

(Formation Example 2) PVC Polyvinyl chloride (P-1300) 100 parts Plasticizer DIDP diisodecyl phthalate 5.5 LK-40 Organic cadmium chelate 0.5 part Cadmium stearate 0.7 Barium stearate 0.3 Colouring agent 0.1 A compoung material of the above mentioned mixture is molded with an extruder.

The clearance between the inclined panels on the cooling water surface is 15 mm. The clearance between the submerged rollers is also set at 15 mm. The filament molding orifice diameter of the die is set at 0.8 mm. The T-die hole arrangement is of four longitudinal rows at the intervals of mm and a lateral orifice pitch of 5 mm. The distance from the T-die t the cooling water surface is 5.5 cm.

The die temperature is 190 C. The die pressure is 80 kg/cm. The extruding Dressure is 190 kg/cm2. The cooling bath temperature is 60 to 80 C. The guide panel temperature is 120 C. Two ceramic far infrared ray heaters of 2.5 KW each are used. At a molding linear speed of 2 m per minute.

loops can be made at a speed of 50 cm per minute can be made.

Thereby, an aggregation in the form shown in Fig. 4(b) of a filament diameter of 1.1 mm. loop diameter of 6 to 10 mm and aggregation thickness of ,4 mm can be molded.

(Formation Example 3) The compound material is the same as in the Formation Example 2.

The respective clearances of the inclined paneis and submerged rolls are made 10 mm.

The die filament orifice diameter is 0.4 mm. The die orifice arrangement is of four longitudinal rows at the intervals of 3 mm and a lateral orifice pitch of 3.5 mm. The distance from the T-die to the cooling water surface is 5 cm.

The die temperature is 185 C. The die pressure is 150 kg/cm. The extruding pressure is 180 kg/cm. The cooling bath temperature is 60 to 80 C. The inclined panel temperature is 120'C. Two ceramc far infrared ray neaters of 2.5 KW each are used. The 17near speed of the filament is set at 3.5 m per minute. The feeding speed is set at 70 cm der minute.

Thereby, an aggregation in the form shown in Fig. 4(c) of a filament diameter of 0.5 mm. loop diameter of 5 to 10 mm and aggregation thickness of 9 mm is molded.

(Formation Example 4) The compound material is the same as ;n the Formation Examole i.

The die orifice arrangement is of four longitudinal rows at the intervals of 5 mm and a lateral orifice Ditch of 5 mm.

The inclined Danel clearance is set at 1 to 13.5 mm. The distance from the T-die to the cooling water surface Is 5 cm.

The die orifice diameter is 0.8 mm. The die temperature is 185 C. The die pressure is 90 kg/cm. The extruding pressure is 190 kg/cm.

Thereby, there is formeo an aggregation in the form shown n Fig. 4(dj in a sandwich state w@erein the front and back parts of the aggregation have flat smooth surfaces, upper and lower loops are formed in the lateral direction and the intertor is of three-dimensional coil structure.

According to this aggregation, there are advantages that. as both front and back surfaces are flat and smooth and are different from ooen coil-like surfaces. shoes or the like will not catch on the surfaces in walking and the resiliency s higher than of general sheets.

It can be applied to a slope for summer skting as another use than for floor mats.

(Formation Example 5) The compound material and other settings are the same as n the Formation ExamDle 4. The clearance between the inclined panels is set at t cm.

Thereby. a filament looo aggregation high in the densite of such structure as of pressed coiled loops is made ano low n resiliency but is high n the strength. It is sheet- like on the surface but is formed of laterally falling direction coiled loops in the interior and is therefore adapted for use as a mat passing soil, sand, rain and water.

Therefore. it is effective for a gate in a place where man people walk. DIfferent from the case when the surface Is of oDen coils, It will not catch on shoes when walking or will not cut loops.

It can be expected to be extensively utilizable for slopes for summer skiing.

(Effects of t-he InventIon) In the mat of the present Invention, since there 18 formed an aggregation of irregular coil-like loops. the individual closed loops will develop resiliency. They are of such Irregular form as a wavy form and are therefore high the degree of contact fusing between the adjacent continuous coiled loops and between the filament forming loops arranged longitudinally and laterally.In the mat in which such loops are formed in the upright direction, in addition to the resiliency of the above mentioned loops themselves, a stiff mat resiliency can be obtained by the strength of the bonded degree between these loops. As such they are suitable for a porch mat or floor sheet.

The mat in which these loops are formed in the laterally fallen direction .s low In resiliency but is hign 'n tensile strength and durability, has clearance spaces sufficient to drop sand, dirt and water debosited on the mat down to tne lower surface and is therefore effective to be used for a long floor sheet 5 an establishment or the like where many people walk ln and out, or for a slope for skiing.

Further, by combining and bonding upright direction loops and laterally fallen loops With each other, there can be obtained a simple convenient practical mat or sheet having characteristies of the individual mat made of both loops described above.

An elastic back sheet pasted to such mat or sheet reinforces the mat elasticity and is so high in the affinity With the set floor surface as to be unlikely to slide or peel off. Particularly. sand and water dropped on the lower surface can be received by the back sheet and the floor surface or the like is not directly dirtied.

When the diameter of the filament in this case 5 set to be in the range of 0.3 to 1.5 mm the practical strength of the filament loop can be obtained and, on the other had. the mat can be made 7h in the sheet weight convenient t the setting work and in the treading touch.

When the major diameter of the loop of an irreguiar 4:orm is adjusted to be n the range of 3 to 15 mm it will be effective 'n keeping the mat elasticity but, on the other hand, if the major diameter of the loop is too large, a shoe tip or like will catch on and out the loop and such danger as falling down will be likely to be caused. Thus. it is not preferable.

In the method of forming a mat or sheet consisting of such filament loop aggregations, the filaments are lowered onto the water surface while near the molding temperature and, when thss water surface is agitated by boiling. the fooDs formed on the water surface will be able to be in such irregular forms as wavy forms and to De contact-fused in the loop intersecting parts and between the loops.

In addition, when the filament bundle falling toward the cool7ng water surface is regulated in width, the sizes of the respective loops formed of these filaments will be made uniform and, when the width as so controlled, the combining of the above described uDright direction loops and laterally fallen loops can be easily made.

When inclined panels are applied as the contracting devices, they will also serve as plates for reflecting the radiation heat from neat sources for holding the temperature t the time of molding the above mentioned filaments. They will be verv effective to keep the temperature of saie filaments and will be simple ano effective devices which will be also laterally fallen loop forming members.

When guide rollers partly exposed on the water surface are used as the contracting devices, a heat reflecting effect will not be expected but. by the filament pulling action by the submerged rollers driving the guide rollers or under free rotation, the filament loops formed on the exoosed peripheral surfaces of the guide rollers will sink into cooling water with little resIstance and therefore the loop forms will not be uselessly disturbed. As a result. thee are very effective to form uniform loop forms over all the range of the aggregation.

The pawled formations on the peripheral surfaces of the above mentioned submerged rollers are desirable to stabilize the speed of the filaments controlled by them an the sinking speed.

If the distance from the die to the cooling water surface is long, the filament temperature will be reduced bv air cooling between them. Therefore, it is desirable to set the distance to be as short as possible. However. if they are too adjacent. the loop formation on the water surface will be disturbed. Therefore. this distance of 5 to 10 cm 18 effective.

By keeping the temperature of the cooling water at a comparatively high temperature of 60 to 80 C. a local boiling state in which the water surface on which the filaments fall is properly waved by heating by the filameents submerging into water can be automatically obtained. In order to smoothly sink the filaments to prevent the loop forms from being disturbed. it is effective to add a surface active agent. By treating the filament loop aggregation on the surface with an adhesive, the practical strength of the mat or sheet can be elevated.

Claims (7)

1. CLAIMS:

   A A mat comprising filament loop aggregations wherein irregularly formed loops are formed by winding filaments an a coil-like fashion such that each of the ends of the loops formed by said filaments bend and are fused and bonded onto a neighbouring loop.
2. 2. A mat comprising filament loop aggregations wherein said loops are situated laterally within said mat and wherein the ends of said loops are bent and bonded and fused to a neighbouring loop.
3. 3. A mat comprising filament loop aggregations wherein a filament loop aggregation consisting of the laterally allen loops according to Claim 2 is overlapped on at least one surface by a filament loop aggregatlon consisting of upright loops according to Claim
4. 4. A mat according to any one Claims 1 to 3 wherein an elastic back sheet consisting of a resin sheet, foamed sheet, resin net-sheet or rubber sheet as adhered to one surface of said filament loop aggregation.
5. 5. A mat according to any one of Claims : to 4 wherein the diameter of sand filament Is In the range of 0.3 to 1.5 mm.
6. b. A A mat according to any of claims 1 to 5 wherein the major diameter of said loop is in the range of 3 to 15 mm.
7. 7. A mat according to Claim 3 substantially as described herein with reference to Figures 4(b), 4(c) or 4(d) of the accompanying drawings.

   7. A mat according to any of Claims 1 to 6 wherein said filament loop aggregations are coated wit a plastisol made of the same material mixture as of said filaments.

   A A mat according to Claim 1 substantially as described -;n any one of the Formation Examples.

   9. A mat comprising filament loop aggregations having ends, said ends being slightly bent such that only one eno of each filament loop ,s bonded to at least the adjacent end of another filament loop, the width of said filament loop aggregations being generally constant throughout.

   10. A mat according to Claim 9 wherein said filament loop aggregations have at least one surface and wherein an elastic back sheet of resin. foam rubber, resin net or rubber is bonded to one surfadce of said filament loop aggregations.

   11. A mat having an upper surface and a bottom surface opposite said upper surface and comprised of filament loop aggregations between said upper surface and said bottom surface, wherein said filament loop aggregations are comprised of a plurality of loops having enos and wherein said ends are generally bent so that the end of the loop 13 bonded and fused to the end of another loop and wherein said filament boos aggregations are coated with a plastisol made of the same material as sand filaments to strengthen said counts of bonding and fusion, the distance between sad upper surface and said bottom surface being generally constant.

   Amendments to the claims have been filed as follows 1. A mat comprising g a substantially uniform thickness aggregation of irregularly shaped filament loops lying against each other across the plane of the mat so as to be substantially upright when the plane of the mat is horizontal, and wherein the edges of the loops in the surface of the aggregation are bent and fused or bonded to a neighbouring loop at the points where the bent edges overlap the neighbouring loop.

   2. A mat comprising a substantially uniform thickness aggregation of irregularly shaped filament loops lying against each other in the plane of the mat so &gamma;s to bt the plane of the mat, and wherein tl edges of the loops in the surface of the aggregation are bent and fused or bonded to a neighbouring loop at the points where the bent edges overlap the neighbouring loops.

   3. A mat comprising a layer of filament loop aggregation as defined in Claim 1 overlapped on at least one surface by a layer of a filament loop aggregation as defined in Claim 2.

   4. A mat according to any one of Claims 1, 2 or 3 in which the filament loops are coated with a plastisol made of the same material as the filament.

   5. A mat according to Claim 1 substan'iially as described herein with reference to Figure 4(a) of the accompanying drawings.

   6. A mat according to Claim 2 substantially as described herein with reference to Figure 4(e) of the accompanying drawings.