JP2630860B2 - Manufacturing method of mud drop mat - 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 manufacturing a mud drop mat to be laid at an entrance of a building or the like.

[0002]

2. Description of the Related Art Conventionally, a mud-off mat composed of a synthetic resin monofilament is disclosed in, for example, Japanese Utility Model Application Laid-Open No. 53-4035.
No. 1, Japanese Patent Publication No. 55-31222 and Japanese Patent Application Laid-Open No. Sho.
It is publicly known, for example, from JP-A-203933.

The one disclosed in Japanese Utility Model Application Laid-Open No. 53-40351,
A monofilament is formed by cutting a three-dimensional net-like aggregate obtained by bending a monofilament into a wavy shape at an intermediate portion in a thickness direction, with the cut portion side as a surface.

In Japanese Patent Publication No. 55-31222, a mat is formed by bringing a group of filaments sinking in a loop form on the surface of a cooling bath into contact with an object intersecting the bath surface at a predetermined angle.

[0005] Japanese Patent Application Laid-Open No. 61-203933 discloses a structure in which elastic filaments continuously extruded in a coil shape are integrated with the direction of the loop thereof being directed at a constant direction by 90% or more. .

As described above, all of the known mats have a single structure as a whole, and have good mud dropping and cushioning properties, but lack mud trapping performance and strength of the substrate portion. There is a problem, and there is a high risk that a small diameter heel, such as a so-called high heel, gets caught in the loop and the shoes come off or the wearer falls over due to the presence of an upright loop on the mat surface. Was something. Therefore, an object of the present invention is to propose a method for efficiently manufacturing a mat that solves these problems.

[0007]

SUMMARY OF THE INVENTION In order to achieve the above object, a method for manufacturing a mud drop mat according to the present invention is provided. The top surface is received in the form of small-diameter loops, and these loops partially overlap and collect with the rotation of the forming roll to form the back layer and the intermediate layer of the mat, and the remainder of the monofilament is the top of the forming roll. Receiving at a water surface lower than the surface , a loop having a larger diameter than the small diameter loop group and having an irregular three-dimensional curve is formed on the intermediate layer, and the respective loops are fused and bonded to each other at intersections to be integrated. This constitutes a mat.

[0008]

[Function] The molten monofilament extruded from the nozzle is deformed from a straight line to a curve in accordance with the stress within the time required for cooling and solidification due to its viscoelasticity due to the application of complex internal stress. Possess the ability to In the present invention, the surface layer of the mat and each layer of the base material (the back layer and the intermediate layer) are formed by different methods depending on the required functions by utilizing such physical properties of the polymer. That is, the cushion of the surface layer exhibits excellent cushioning properties due to the flexibility of the loop of the surface layer and the elasticity of the intermediate layer and the back surface layer, so that a comfortable feeling can be obtained when walking. Also,
The mud wiped from the shoes settles down from the loop part of the surface layer to the middle layer and the back layer sequentially, but is stored in the mat due to the dense structure of the middle layer and the back layer, and is discharged under the mat. The amount is small and the cleaning workability is good. further,
Less set and deformation during use.

[0009]

An embodiment of the present invention will be described below with reference to the drawings. In FIG. 1, reference numeral 1 denotes an extruder for melting soft vinyl chloride, and a spinning pack 2 is connected to the tip of the extruder. , And monofilaments F1 to F5 spun from these nozzles are hung straight down. In these monofilaments, the front F1 forms the back surface layer IL of the mat, and the F2, F
3 and F4 form the intermediate layer ML of the mat, and the rearward F5
Is used to form the surface layer AL of the mat. 3
Are forming rolls for forming loops L1 to L4 in each of the monofilaments F1 to F4, and are installed below the spinning pack 2 so that the hanging distance of each monofilament F1 to F4 is 30 to 35 mm. And rotate it in the direction of the arrow. Reference numeral 4 denotes a guide roll of the base mat formed by the forming roll 3, which is positioned and installed so that the base mat can move vertically, and rotated in the direction of the arrow.
5 is a delivery roll. 6 is a cooling water bath to accommodate the molding roll 3 and guide roll 4, to adjust the water surface 7 of the cooling water to the height of the lower 35~45mm the nozzle surface. In addition,
The temperature of the cooling water is preferably set to 83 to 87 ° C.

[0010] Among the monofilaments manufactured under such manufacturing conditions, the monofilament F1 hangs down from the nozzle to the top surface of the forming roll 3 to form a small annular continuous loop L1. The loops are fused at the intersections to form the back surface layer IL. And as mentioned above
A loop L2 is formed by the monofilament F2 on the formed back surface layer IL, and the intersection of the loop L2 and the loop L1 of the monofilament F1 is fused. Hereinafter, in the same manner, the monofilament F
3, and the monofilament F4 is sequentially looped L3, L
4 and are fused at the intersections with the preceding loops to form an intermediate layer ML of mat with monofilaments F2, F3 and monofilament F4. This intermediate layer ML and the back layer I
Mat base by the L is formed integrally with, weldable at high temperatures
It is transferred into the water surface 7 with the rotation of the forming roll 3 in a state. On the other hand, monofilaments F5 is formed by a loop L1~L4 before Symbol monofilament F1~F4 backside
The position where the layer IL and the intermediate layer ML are transferred into the water surface 7
And larger loop L5 from L1~L2 it is Ru formed.
Then , in the loop L5 , the monofilament overlaps on the loop L4 of F4, and is fused at the intersection of each other. Next, the loop L5 of the monofilament F5 is transferred straight into the water, and is gradually cooled and fixed in the water to be deformed and deformed, thereby forming a three-dimensional complicated curved shape, and a mud-off mat M having the shape shown in FIGS. 2 and 3 is formed. . The size of the loops L1 to L4 formed by the monofilaments F1 to F4 is such that the shorter the length of the respective hanging distances to the forming roll 3 having a curved surface, the smaller the loop diameter becomes. F4 of
The monofilaments are not the same loop diameters but are different, and the monofilaments F forming the surface layer AL are different.
5 droop distance loop L 5 with the largest diameter because it is on the water surface 7 of
Is formed.

[0011] The mud-dropping mat M thus constructed is
The surface layer AL forms a three-dimensional curve by the monofilament F5, has a good cushioning property, is excellent in mud catching performance, and does not catch the heel. Further, the intermediate layer ML and the back layer IL are provided with multi-stage small annular loops L1 to L4 for restricting the passage and settling of mud by F1 to F4, so that such a mat can be manufactured continuously.

FIG. 4 shows a convex pattern P on the back surface.
And a draining mat having improved drainage. The mat is manufactured continuously using a forming roll 3 engraved with a concave pattern H on the surface as shown in FIG. Can be. Thus mat having a convex pattern P on the rear surface in addition to the drainage improvements, bulk transfection resistance is further improved by increasing the shock absorbing during Stepping pressure is further improved.

In the present invention, the size and shape of the loop and the angle of the loop of the surface layer can be easily changed by slightly changing the mounting height of the forming roll and the height of the water surface. Structured mats can be manufactured.

[0014]

Method for producing a mud off mat of the present invention as described above, according to the present invention, the surface layer of the mat produced, loops each mode Nofuiramento the intermediate layer and back layer are formed size and shape Has a different composite structure, has excellent cushioning properties, has a good mud trapping efficiency,
The mud that has fallen from the shoes sinks down on the surface layer without being caught by the heel, and is collected and retained in the intermediate layer, so that the floor surface can be kept clean. Moreover, without causing deformation such as sag it has strength superior, can be stably used over a long period of time.

[Brief description of the drawings]

FIG. 1 is a schematic diagram of an apparatus structure suitable for producing a mud-off mat.

FIG. 2 is a perspective view of a mud mat.

FIG. 3 is a side view of the same.

FIG. 4 is a perspective view of the back surface of a mud-drop mat having a convex pattern formed on the back surface.

FIG. 5 is a side view of the same.

6 is a perspective view of the molding roll to form a scraping mat shown in FIG.

[Explanation of symbols]

3 Forming roll 7 Water surface F1 to F5 Monofilament AL Surface layer ML Intermediate layer IL Back layer H Concave pattern P Convex pattern L1 to L5 Loop

Claims (2)

(57) [Claims] 1. A large number of synthetic resin molten monofilaments are hung down, and a part thereof is received as a small-diameter loop on the top surface of a rotating forming roll, and these loops are partially formed as the forming roll rotates. overlap set to allowed formed backside layer and the intermediate layer of the mat, the rest of the monofilament is also irregular only larger diameter than the loop group of the small-diameter on said intermediate layer and received at a lower water level than the top surface of the forming roll Characterized in that a surface layer is formed by loops composed of various three-dimensional curves, and the loops are mutually fused and integrated at intersections to constitute a mat that is integrated. . 2. A forming roll having a concave pattern formed on its surface.
The method for producing a mat for removing mud according to claim 1, wherein a convex pattern is formed on the back surface of the mat by using the mat.