JP2571529B2 - Mat production method - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for efficiently producing a mat having a groove-shaped decorative pattern formed on a surface formed by laminating a large number of synthetic resin monofilaments in a loop. The present invention also provides a method for producing a mat having functions such as stable antibacterial, antifungal, antialgal, insect and antistatic functions.

[0002]

2. Description of the Related Art Conventionally, a mat formed by a loop group of a large number of synthetic resin monofilaments has been known. However, no such mat is provided with a groove-shaped decorative pattern on the surface and further provided with functions such as antibacterial, antifungal, algal, insect and antistatic properties.

[0003]

For this reason, the use of conventional mats is limited. For example, hospitals, clean rooms, kitchens, restaurants, poolsides, bathrooms, etc., require special hygiene considerations. It was not used anywhere, and was limited to mud-drop mats that were installed and used exclusively at building entrances. Therefore, an object of the present invention is to provide a method for efficiently producing a mat having functions such as anti-bacterial, anti-fungal, anti-algal, anti-insect and antistatic which can solve such problems.

[0004]

According to the method of manufacturing a mat of the present invention, a cooling water tank is provided below an extruder provided with a spinning pack in which a plurality of nozzles are arranged at mutually shifted positions, and a concave pattern is formed in the cooling water tank. A shaping roll and a convex shaping roll are opposed to each other, and the cooling water tank is filled with cooling water to a depth at which a surface where the concave shaping roll and the convex shaping roll are in contact with each other is submerged. Ethanol was added to the cooling water, a large number of synthetic resin monofilaments spun from each of the nozzle groups were hung down, and a part of the monofilaments was received in a loop on a convex shaping roll to form a back surface layer, and a monolayer of the monofilament was formed. A surface layer is formed in a loop shape on the back surface layer in the remaining portion, and the loops are fused and bonded to each other at intersections to form a mat. In shape Forming a groove-like decorative pattern I, then heated and dried by pulling draining the cooling water tank the mat,
Further, the present invention is characterized in that a paste is applied to the entire surface of the mat by spraying or the like, and then heated while passing through a drying oven to dry and cure the paste.

[0005] The invention of claim 2 is based on claim 1.
In the invention of the, the step of manufacturing a mat, the step of applying a paste to the manufactured mat and drying and curing is divided,
This is a mat production method using two batches.

According to a third aspect of the present invention, in the first and second aspects of the present invention, instead of adding ethanol to the cooling water, a convex-shaped shaping roll and a concave-shaped shaping roll are used. This is a method of manufacturing a mat supplied on the surface by dropping or spraying.

[0007] Further, the invention of claim 4 is the above-mentioned claim 1.
A method for producing a mat according to the invention of claim 2 or claim 2, wherein an antibacterial agent, a fungicide and an antialgal agent are mixed into a paste applied to the entire surface of the mat.

A fifth aspect of the present invention is a method for producing a mat according to the first and second aspects of the invention, wherein an insect repellent and a fragrance are mixed in a paste applied to the entire surface of the mat. .

Next, the invention according to claim 6 is the invention according to claim 1.
A method for manufacturing a mat according to the invention of claim 2 or claim 2, wherein a conductive plasticizer is mixed into a paste applied to the entire surface of the mat.

[0010]

[Action] The molten monofilament extruded from each nozzle hangs down on the surface of the cooling water tank, and the viscoelastic molten monofilament is cooled and solidified in water within a period of time.
The ability to deform from a straight line to a curve in accordance with the stress is stored, and a random loop group is laminated by a concave pattern forming roll and a convex pattern forming roll opposed to each other in the cooling water tank,
A mat in which a decorative pattern is formed on the front surface by a concave groove and on the back surface by a ridge is formed. Then, by adding ethanol to the cooling water in the cooling water tank to lower the surface tension, the molten monofilaments extruded from the nozzles drop down to the surface of the water to form a loop, so that the settling of the loop is smooth. Therefore, the layers are stacked in a uniform shape without disturbing the loop shape. The mat thus formed is pulled up from the cooling water tank, drained, heated and dried, a paste is applied to the entire surface, and the paste is dried and hardened to obtain a product having a high tensile strength.

Further, if ethanol is not added to the cooling water but dripped or sprayed onto the surface of the concave-shaped shaping roll and the convex-shaped shaping roll as in the third aspect of the present invention, the portion where the molten monofilament hangs down. The surface tension and the temperature of the cooling water can be locally reduced, and the settling of the loop is performed smoothly, and the layers are stacked in a uniform shape without disturbing the loop shape.

If an antibacterial agent, a fungicide and an antialgal agent are mixed into the paste as in the invention of claim 4, the antibacterial and fungicide can be produced by the method for producing a mat according to claims 1 and 2. Thus, a mat having properties and anti-algal properties suitable for a wide range of applications can be obtained.

Further, when an insect repellent and a fragrance are mixed in the paste as in the invention of claim 5, a mat having insect repellency and deodorant properties can be obtained by the method for producing a mat of claims 1 and 2. Can be

Then, if a conductive plasticizer is mixed into the glue as in the fifth aspect of the present invention, a mat having antistatic properties can be obtained by the method for producing a mat according to the first and second aspects.

[0015]

An embodiment of the present invention will be described below with reference to the drawings. In FIGS. 1 and 2, reference numeral 1 denotes an extruder for extruding a soft vinyl chloride resin, and a spin pack 2 is provided at the tip of the extruder.
And three rows of nozzle groups (not shown) are arranged below the spinning pack 2 with their positions shifted from each other, and rows F1 to F3 of monofilaments spun from these nozzle groups.
Is hung straight down. In these monofilament rows, the rear F1 forms the back layer L of the mat, and the front F1
2 and F3 form the surface layer A of the mat.

3 is a row F1 to F of each of these filaments.
3 is a convex-shaped shaping roll for receiving and forming a loop in each of the spinning packs 2.
And rotate it in the direction of the arrow. As shown in FIG. 3, the convex pattern shaping roll 3 is formed by providing a concave groove 4 in a grid shape on the peripheral surface and a concave groove 4 'for an English character or the like. 5
Is a concave pattern forming roll which is disposed so as to rotate in the direction of the arrow shown in FIG. 2 in opposition to the convex pattern forming roll 3, and has a ridge 6 on its peripheral surface as shown in FIG. It is formed at 45 degrees in the axial direction and at equal intervals. Numeral 7 is a guide roll of the mat sent out from a pair of the convex shaping roll 3 and the concave shaping roll 5, which is provided so as to be positioned so that the mat M can move vertically, and is rotated in the direction of the arrow shown in FIG. . Reference numeral 8 denotes a mesh conveyor that receives and transports the mat M that has passed through the guide roll 7, and a belt wheel 9 for supporting the left end is located below the guide roll 7, and a belt wheel 9 'for supporting the right end is a belt conveyor 9'. It is installed at a high position, stretched and inclined to the upper right, and positioning rollers 10, 10 'are interposed at two intermediate points to maintain the level near the belt wheel 9'.

Numeral 11 denotes a cooling water tank for accommodating the convex shaping roll 3, the concave shaping roll 5, the guide roll 7, and the lower half of the mesh conveyor 8, and has a constant temperature (50-60 ° C.) inside. Is stored. The cooling water is set to a temperature at which the monofilament rows F1 to F3 spun out from the nozzles of the spinning pack 2 are gradually cooled without being rapidly cooled, so that a uniform loop is formed.

The water temperature of the cooling water tank 11 is adjusted as follows. That is, an outflow pipe 12 communicating with the inside is provided at an upper part of one side wall of the cooling water tank 11, and an inflow pipe 13 is similarly connected to the circulation pump 14 and the hot water heater 1 at the lower part.
5 and a water supply pipe 17 provided with a cooling supply valve 16 behind the hot water heater 15. In addition, a water temperature controller 18 is provided above the cooling water tank 11, and the detection section at the lower end is immersed in water. And water temperature controller 1
8, the water in the tank is drawn into the hot water heater 15 from the inflow pipe 13 and heated, and the heated hot water is discharged into the outflow pipe 12
Or by opening the cooling supply valve 16 and allowing the cold water sent from the water supply pipe 17 to flow into the tank from the outflow pipe 12 so that the water temperature of the cooling water tank 11 is adjusted and kept constant. To Further, by adding 10% to 40%, preferably 30% of ethanol to the cooling water, the surface tension of the water surface 19 of the cooling water tank 11 is reduced, and the rows F1 to M5 of the molten monofilaments extruded from the nozzle are reduced.
F3 is settled smoothly and the layers are uniformly stacked without disturbing the loop shape. The water surface 19 of the cooling water tank 11 is adjusted so that the surface where the convex pattern forming roll 3 and the concave pattern forming roll 5 are in contact with each other has a depth of submersion.

The take-off rolls 20 and 20 ′ are provided on the outer upper side of the cooling water tank 11 near the end of the mesh conveyor 8, and an ear cutter 22 is disposed below the idler roll 21 via the idle roll 21. A belt conveyor 25 horizontally supported by belt wheels 24 and 24 ′ is installed below the ear cutter 22 via a press roll 23, and a belt conveyor 26 is further coaxial with the belt conveyor 25. , 27 '. The upper surface traveling portion 26a of the belt conveyor 26 travels in the drying furnace 28. A multi-stage blower 29 is provided before the entrance of the drying furnace 28, and a cooling fan 3 is provided on the exit side of the drying furnace 28.
0 are respectively set. 31 is a guide roll, 3
2 is a winder.

In the row of monofilaments extruded from the spinning pack 2, F1 hangs down to reach the surface of the convex shaping roll 3 to form a small annular continuous loop while forming the continuous loop. 3, and the adjacent loops are fused at intersections. As described above, the monofilament row F2 hangs down on the entire surface of the back layer L formed by the monofilament row F1 to form a loop, and the intersection of this loop and the loop formed by the monofilament row F1 is fused to form a loop. Is transferred to the water surface 19 with the rotation of the convex shaping roll 3 in a fusible state.

On the other hand, a row of monofilaments F3 hangs down from the water surface 9 close to this position, and a loop larger than the loop formed by the monofilament rows F1 and F2 transferred to the water surface 9 is formed. Overlap on the loop by the monofilament row F2,
The surface layer A of the mat M is formed by fusing at intersections of each other. Subsequently, the surface layer A is pressed and shaped by the concave pattern forming roll 5, and further pressed by the convex pattern forming roll 3 to form the mat M. The mat M thus formed
On the back side, a checkerboard-like convex portion is formed by the concave groove 4 of the convex pattern shaping roll 3, and the English character appears in an embossed shape by the concave groove 4 '. Then, on the surface of the mat M, concave grooves H of diamond-shaped cells are formed by the ridges 6 of the concave pattern forming roll 5. (See FIGS. 6 and 8)

The mat M is subsequently suspended in water and the loops are cooled, deformed and solidified to form a complicated three-dimensional curved shape. The loops are transported by a mesh conveyor 8 through guide rolls 7 and cooled in a cooling water tank. 11, the pair of take-up rolls 20 and 20 ′ take up the pair, and then the both ears are cut by the ear cutter 22. The mat M whose both ears were cut and the width was constant was received by the belt conveyor 24 and, while being transferred, the ethanol was evaporated by the blowing from the multistage blower 29 in front of the entrance of the drying furnace 28, and the draining was completed. The material is heated and dried in the process of traveling on the drying oven 28 on the belt conveyor 26. Drying oven 28
The mat M coming out is cooled by a cooling fan 30 and wound up in a roll by a winder 32.

FIG. 5 shows an apparatus configuration for applying a paste to the long mat M manufactured by the apparatus configuration shown in FIG. In the same figure, reference numeral 33 denotes a feeder for sequentially feeding a long mat M, and reference numeral 34 denotes a feed belt for sending the mat M fed from the feeder 33 to a gluing mechanism. Both ends are supported by a pair of belt wheels 35, 35 '. The pressing roll 36 is provided above the belt wheel 35 '. Reference numeral 37 denotes a glue tank, in which the glue P is stored. Numeral 38 denotes a glue supply pipe which feeds the glue in the glue tank 37 up to a predetermined height position, and has a nozzle 39 connected to the tip.
The glue P is pumped up by a glue pump 41 driven by a motor 40.

Reference numerals 42, 42 denote a pair of upper and lower squeezing rolls, and a doctor plate 43 for scraping the adhesive P is disposed on a roll located below. Reference numeral 44 denotes a brush for brushing the back surface of the mat M to remove excess glue P.
Reference numeral 45 denotes a feed belt having both ends supported by a pair of belt wheels 46, 46 '. A doctor plate 47 for scraping off the adhesive P attached to the feed belt 45 is attached to the side of the belt wheel 46', and is scraped down below. A glue container 48 for collecting the glue P is arranged. The glue P collected in the glue container 48 is returned to the glue tank 37 and sprayed again by the glue feed pump 41 on the surface of the mat M from the nozzle 39 via the glue supply pipe 38.

Reference numeral 49 denotes a conveyor belt whose both ends are supported by belt wheels 50, 50 '. A drying furnace 51 is installed with the upper running portion 49a of the conveyor belt 49 interposed therebetween.
A cooling fan 52 is disposed above the outlet of the cooling fan. 53,5
Reference numeral 3 'denotes a receiving roll of the mat M sent from the conveyor belt 49. 54 is a belt wheel 55, 55 'at both ends.
Reference numeral 56 denotes a winding machine for the mat M. The winding machine 56 forcibly rotates a center roll of the plurality of rolls 57 with a motor 58,
The mat M is wound up into a roll.

The mat M is fed from the feeder 33 at a feed speed of 0.6 to 1.5 m / min, supplied to the gluing mechanism via the feed belt 34 and the presser roll 36, and has a glue supply pipe 38 The paste P is sprayed from the nozzle 39. The amount of glue used is 0.5-1 kg / m ² . The glue P applied by spraying is removed of excess by squeezing rolls 42, 42, and then the back surface of the mat M is brushed by a brush 44. Next, the mat M is sent to the conveyor belt 49 via the feed belt 45,
The paste P is dried and hardened in the process of passing through the drying furnace 51 heated to 70 ° C. The glue P is adhered to each loop of the mat M by spraying by the nozzle 39, and forms a strong resin film by hardening.
The mat M coming out of the drying furnace 51 is cooled by a cooling fan 52 and then wound up by a hoist 56.

The mat M thus formed long
As shown in FIG. 6, a concave groove H of a diamond-shaped mesh is formed on the entire front surface, and a base-like convex ridge R is formed on the entire back surface as shown in FIG. Then, a long object is cut into required dimensions according to the place of use and is laid and used.

Further, when a product provided in a specific size, such as a door mat, is cut by pressing with a frame-shaped cutter for cutting into a fixed size, as shown in FIGS. At the same time, the peripheral edge of the product G is compressed on both the front and back surfaces to form the frame-shaped edge decoration B, and at the same time, the peripheral edge is welded and does not fray. Since the compressed portion of the mat M is formed in a loop shape, a loop-shaped pattern is formed on the frame-shaped edge decoration B when the periphery is compressed.

In the method for manufacturing a mat according to the first aspect, the winding machine 32 shown in FIG. 1 and the drawing machine 33 shown in FIG.
Can be directly connected, and at the same time as the production of the mat M, the sizing and the drying and curing thereof can be continuously performed.

The method for manufacturing a mat according to the second aspect comprises two separate steps as shown in the apparatus configuration shown in FIGS. By dividing the manufacturing process in this manner, the layout and space for installing the apparatus can be made more efficient, and the process management and the like can be further facilitated.

Further, as shown in FIG. 9, an ethanol supply device 59 is installed below the spinning pack 2 as shown in FIG. By supplying the solution to one or both surfaces of the device 5 by dropping or spraying, it is possible to reduce the consumption of ethanol as compared with the case where ethanol is added to the entire cooling water, thereby contributing to a reduction in cost cost. .

Furthermore, an antibacterial agent, a fungicide, and an anti-algal agent are mixed in the paste as in claim 4, to thereby provide the paste in claim 1.
According to the method for producing a mat of the present invention, a mat having antibacterial properties, fungicidal properties and anti-algal properties can be obtained.

Similarly, by mixing the insect repellent and the fragrance into the paste as described in claim 5, a mat having insect repellency and deodorant properties can be obtained by the method for producing a mat according to claims 1 and 2.

Then, by mixing the conductive plasticizer into the paste as in claim 6, a mat having antistatic properties can be obtained by the method for producing a mat according to claims 1 and 2.

[0035]

As described above, in the mat obtained by the production method of the present invention, by using ethanol for the cooling water in the cooling water tank, a uniform loop can be formed without disturbing the loop shape laminated on the mat surface. It is formed, and when glue is applied, the loop groups are securely joined to increase the adhesive strength. A mat sprayed with an antibacterial agent, a fungicide and an anti-algal agent into a paste and sprayed together with the paste is used in hospitals,
Ideal for use in places requiring hygienic considerations such as clean rooms, kitchens, restaurants, poolsides, around bathrooms, and moreover, antibacterial, antifungal, antialgal, and effects mixed in paste Since the antibacterial agent, fungicide, and antialgal agent have an amorphous structure having metal ions, the metal ions are gradually released, thereby providing a strong antibacterial effect (prevents offensive odor, sliminess), antifungal and antialgal effects. Demonstrate. Furthermore, these antibacterial, fungicidal and anti-algal functions are excellent in safety, heat resistance, light resistance and durability, and can be used stably for a long time in the above-mentioned applications. In addition, a mat formed by mixing an insect repellent and a deodorant into a paste can be used for various pets and household mats to provide an effect on insect repellency and deodorization. In addition, mats formed by mixing a conductive plasticizer into a glue may cause an explosion or fire due to its antistatic properties, as in operating rooms, flammable gas and solvent storage rooms, and in the process of handling them. Certain danger areas, places where there is a risk of electric shock such as powder bag packing process, paper winding process, and places where production obstruction may occur such as computer room, semiconductor handling area, etc. Can be used for As described above, the mat obtained by the production method of the present invention has a remarkably wide range of suitable uses due to its excellent performance.

[Brief description of the drawings]

FIG. 1 is a schematic structural view of an apparatus for manufacturing a mat.

FIG. 2 is a partially enlarged view of FIG. 1;

FIG. 3 is a perspective view of a convex shaping roll used in the manufacturing apparatus of FIG. 1;

FIG. 4 is a perspective view of a concave pattern forming roll used in the manufacturing apparatus of FIG. 1;

FIG. 5 is a schematic structural diagram of an apparatus for gluing a mat manufactured by the manufacturing apparatus of FIG. 1;

FIG. 6 is a front perspective view of a mat manufactured by the manufacturing method of the present invention.

FIG. 7 is a front perspective view of a product obtained by cutting the mat shown in FIG. 6 into rated dimensions.

FIG. 8 is a perspective view of the same back surface.

FIG. 9 is a partially enlarged view of a mat manufacturing apparatus provided with an ethanol supply device.

[Explanation of symbols]

 REFERENCE SIGNS LIST 1 extruder 2 spinning pack 3 convex shaping roll 5 concave shaping roll 11 cooling water tank 19 water surface 39 nozzle 51 drying furnace 59 ethanol supply device Glue

Continuation of the front page (51) Int.Cl. ⁶ Identification number Office reference number FI Technical display location D06M 15/00 D06M 15/00

Claims (6)

(57) [Claims] 1. A cooling water tank is provided below an extruder provided with a spinning pack in which a plurality of nozzles are arranged at mutually shifted positions, and a concave pattern forming roll and a convex pattern forming roll are opposed in the cooling water tank. Further, the cooling water tank is filled with cooling water to a depth at which the surface facing the concave pattern forming roll and the convex pattern forming roll are submerged, and ethanol is added to the cooling water,
A large number of synthetic resin monofilaments spun from the respective nozzle groups are hung down, and a part of the monofilament is received in a loop by a convex shaping roll to form a back surface layer, and the remaining monofilament forms a loop on the back surface layer. A surface layer is formed on the mat, and the loops are fused and bonded to each other at intersections to form a mat, and a concave groove-shaped decorative pattern is formed on the surface layer of the mat by pressing a concave pattern forming roll. The mat is pulled up from the cooling water tank, drained and dried by heating, and further, a paste is applied to the entire surface of the mat by spraying or the like, and then heated while passing through a drying oven to dry and cure the paste. A method for producing a mat, comprising: 2. A cooling water tank is provided below an extruder provided with a spinning pack in which a plurality of nozzles are arranged at mutually shifted positions, and a concave shaping roll and a convex shaping roll are opposed in the cooling water tank. Further, the cooling water tank is filled with cooling water so that the surface where the concave pattern forming roll and the convex pattern forming roll contact each other is submerged, and about 10% to 40% of ethanol is added to the cooling water. A large number of synthetic resin monofilaments spun from each of the nozzle groups are drooped, and a part of the monofilaments is received in a loop by a convex shape forming roll to form a back layer, and the remaining monofilament is looped on the back layer. A mat is formed by laminating and forming a surface layer in a shape and fusing the loops to each other at intersections.
A first step of forming a concave groove-shaped decorative pattern on the surface layer of the mat by pressing and shaping a concave pattern shaping roll, pulling up the mat from a cooling water tank, draining it, heating and drying, and winding it into a roll; The mat formed by winding up in a roll in one process is sequentially supplied from the payout machine to the sizing device, and the sizing agent is applied by spraying or the like, and then heated while passing through a drying oven to dry and harden the sizing agent. And a second step of winding the mat. 3. The method according to claim 1, wherein instead of adding ethanol to the cooling water, the ethanol is supplied to the surfaces of the concave-shaped shaping roll and the convex-shaped shaping roll by dropping or spraying. Mat production method. 4. The method for producing a mat according to claim 1, wherein an antibacterial agent, a fungicide and an antialgal agent are mixed in the paste. 5. The method for producing a mat according to claim 1, wherein an insect repellent and a fragrance are mixed in the paste. 6. The method for producing a mat according to claim 1, wherein a conductive plasticizer is mixed into the sizing agent.