JPH02106316A - Manufacture of floor mat - Google Patents

Abstract

PURPOSE:To constitute a network structure mat molding being in contact with each other at a constant distance by limiting such that each nozzle being disposed in a rank on the T-die of an extrusion molding machine is swingable with respect to the extrusion face of a molding material, and the swinging face to an adjacent nozzle conducts a counter periodical motion. CONSTITUTION:Each nozzle 1a, 1b...1n being disposed in a rank (about 54-90pieces) to the main body of a T-die is constituted to be swingable with respect to their molding extrusion faces, and limited such that the swinging faces of the nozzle 1a, 1b...1n adjacent to each other are in opposite directions. Herein, each streak-shaped molding extruded from each nozzle winds such as waves, and forms a continuous length molding in succession. And, by accelerating the transporting speed of a conveyor transporting a network molding with respect to the extruding speed of streak-shaped moldings, there may arise the tensile operational force of the extrusion face to the meandering form moldings, and patterns can be thus be deformed thereby.

Description

[Detailed Description of the Invention] [Industrial Application Field] The present invention relates to a method for manufacturing floor mats, and in particular, to a method for manufacturing floor mats, in particular, a mesh made of a soft synthetic resin material is used to remove soil, dust, and moisture attached to the soles of shoes, etc. The present invention relates to a means for obtaining thick mats of the same size.

[Conventional technology]

Floor mats that are placed in entrances or floors to remove soil, dirt, and moisture that adhere to the soles of visitors' shoes due to the brushing action on the soles of visitors' shoes are those that have a fibrous surface such as carpet, or A plate-shaped body made of metal or a hard synthetic resin material with many openings formed on the surface is used.

Among these, the mat made of the fibrous surface.

It has an excellent brushing effect on the soles of shoes, etc., and is advantageous for wiping off dirt and water, but on the other hand, it has disadvantages, such as dirt that has been wiped off remaining on the surface of the mat, causing clogging of the tan-shaped part. On the other hand, mats made of hard synthetic resin with penetrating openings are superior in that they can be kept in a proper condition at all times by eliminating the residual soil or moisture that has been wiped off. However, since the elasticity against stepping on the mat is poor, the feeling of walking on the mat is poor, and the brushing action is reduced, so it is not effective in removing dirt.

Under these circumstances, a composite floor mat has been proposed that combines the advantages of the mat made of the m-male surface and the advantages of the mat made of hard synthetic resin.

[Problem to be solved by the invention]

In the above-mentioned known composite mat, since brush-like bristles are densely grown in the openings of the metal or hard synthetic resin mat, the product is bulky and heavy.
In addition to being inconvenient to store and transport, walking on upright bristles gives a poor walking feel.Furthermore, a backing board is required for the dense bristles arrangement, so the function of preventing soil from remaining remains is still poor. Not enough.

Therefore, one object of the present invention is to provide a method for manufacturing a mat made of synthetic resin having this type of through opening, and in particular to provide a means for obtaining a thick floor mat made of soft synthetic resin with a simple structure. There is a particular thing.

[Means to solve the problem]

According to the present invention, in forming a plurality of strip-shaped molded bodies arranged in rows by an extrusion molding machine using a thermoplastic soft synthetic resin as a material, each nozzle arranged in rows in a T-die of the extrusion molding machine The nozzles are able to swing freely relative to the extrusion direction of the molded material, and are regulated so that the swinging directions of adjacent nozzles among these nozzles are periodic motions in opposite directions. A first processing means for continuously forming mesh-like elongated molded bodies in which each of the strip-shaped molded bodies extruded from the nozzle snakes and fuses between adjacent molded bodies at a predetermined interval based on the period. and a second processing means for accelerating and decelerating the conveyance speed of a conveyor that is located immediately in front of the T-die and that transfers the mesh-like molded body with respect to the extrusion speed of the strip-shaped molded body. This can be achieved by a method.

Furthermore, a third method in which the nozzle is configured in a replaceable cartridge type, and a mesh-like molded body having a different cross-sectional shape of the strip-shaped molded body is formed using various nozzles having different extrusion opening shapes.
It is effective to use these processing means together.

[For production]

Each nozzle, which is swingably attached to the T-die, rotates and reciprocates in opposite directions so that the strip-shaped molded product extruded from these nozzles can be controlled within a predetermined amplitude range. Make it meander within.

Moreover, the range of the reciprocating movement of each nozzle,
By setting the tips of adjacent nozzles so that they are close to each other, the strip-shaped molded bodies come into contact with the adjacent strip-shaped molded bodies at the maximum amplitude position and are fused together at this part. act.

Thus, in the first processing means, a molded body having a mesh-like structure is obtained by a large number of strip-shaped molded bodies, and in contrast, in the second processing means, the mesh-shaped molded body is transferred. By adjusting the speed with respect to the extrusion speed of the strip-shaped compact, a tensile force in the extrusion direction is generated in the meandering strip-shaped compact.

Therefore, this second processing means effectively functions to transform the mesh pattern of the mesh molded body.

Furthermore, if the third processing means is used in combination, in addition to deforming the mesh pattern, it is possible to change the cross-sectional shape of the strip-shaped molded body forming the pattern, and the deformation of the mesh pattern by the second processing means In combination with changing the cross-sectional shape of the strip shaped body by the third processing means, it becomes possible to form floor mats having a wide variety of pattern shapes.

〔Example〕

Next, preferred embodiments of the present invention will be described with reference to the accompanying drawings.

Fig. 1 is a schematic diagram showing the manufacturing process of a floor mat according to the present invention, in which a molded product from T-die B of extrusion molding machine A, which pressurizes a thermoplastic soft synthetic resin heated to 2006C to 150'C, is fed five times. Fence conveyor C with controlled speed
The reticulated molded product is sent to a cooling machine consisting of a water tank using a whirlpool water tank, and is then transported by a transport roller E in the middle and a transport roller J at the end. Coating machine G, drying oven H and cooling chamber I are installed to complete the product, which is then transferred to winding machine K.
It is not possible to continuously produce a long floor (my) product by rolling it up one after another.

FIG. 2 is a plan view of T-die B in the above manufacturing process, and each nozzle la, lb...1n, Φ arranged in horizontal rows (approximately 54 to 90 nozzles) on the main body of T-die B is Nozzles 1a, 1b, 1b, . . . in .
The direction of the swing is regulated to be in the opposite direction.

That is, any nozzle 1° structure in the T-die B is formed into an immovable main body 4 having an introduction path 2 for the resin molding material and an expansion chamber 3 at its tip, as shown in the longitudinal cross-sectional side view of FIG. , a hollow part with a semicircular cross section in which the expansion chamber 3 is formed in a part of the peripheral wall is provided, and the nozzle 1n in the center thereof, a boat 6 communicating with the nozzle 1n, and an introduction lower opening in the shape of a funnel at one end thereof. The cylindrical body 8 comprising the above-mentioned structure is placed below the hollow part with the introduction lower aligned with the expansion chamber 3.

Further, core shafts 9a and 9b extending from both ends of the cylindrical body 8
The upper and lower support plates 10a function as a body and support the columnar body 8 from below.

10b is integrally attached to one main body 4 by pol) lla and flb, respectively.

A gear 12 is attached to one of the core shafts 8a and 3b, for example, the core shaft 9a of the nozzle 1n, at the shaft end protruding from the support plate 1a.

Note that this gear 12 meshes with a rack 13, which will be described later.

Therefore, as the gear 12 rotates in the forward and reverse directions within a predetermined rotation angle range (60° to 90') due to the back and forth movement of the rack 13, the cylindrical body 8 rotates in the forward and reverse directions. The expansion chamber 3 and the introduction lower are kept in communication with each other in the intermediate chamber, so that the molded body 14 extruded from the nozzle 1n is in a meandering state over a predetermined width, as shown in FIG. When the extrusion speed at this time and the speed at which the molded body 14 and the molded body 14 are placed on the 7th conveyor C and sent are the same, this meandering becomes a sine wave shape, and by increasing the feeding speed slightly from this, the illustrated It becomes a chevron wave shape.

Moreover, when this nozzle 1n and the adjacent nozzle l11-1 swing in opposite directions and are in such a state that both nozzles i11 and 1.1.1 come into contact with each other at the maximum swing position, these nozzles Molded body 14, 1 extruded from
4 touch each other at the tops of the chevron waves, and as a result, they fuse at these abutting parts that are still close to the forming temperature and in a softened state, so that the chevron wave shape can be formed more reliably at the above-mentioned feed rate. becomes.

FIG. 5 is a configuration diagram showing an example of a drive device that controls the swinging motion of the nozzles ta, lb...In... A bevel gear 19 is attached to the reduced drive shaft 18, and eccentric shafts 23 are installed at symmetrical positions around each of the driving wheels 22a and 22b, which are integrated with another bevel gear 20 that meshes with the rotating shaft 21 and the pair of drive wheels 22a and 22b. are provided, to which one end of the crank lever 24 is rotatably attached.

Reference numeral 25 denotes a slide frame plate with a guide groove 2B, which has a slider 27 slidably fitted into the groove 2B, and the other end of the crank lever 24 is rotatably attached to the slider 27. The extended end of the rack 13 is attached.

Moreover, this rack 13 is connected to the previous driving wheels 22a, 22.
For example, every odd nozzle In has a gear 12 of a core shaft 8a projecting upward. and the upper rack 13 engage with each other, and the core shaft 9 protrudes downward in the even-numbered nozzle In-1.
The gear 12 b and the lower rack 13 are arranged so as to mesh with each other.

Therefore, when the drive wheels 22a and 22b rotate in the same direction at a constant speed, the upper and lower crank levers 24 supported at symmetrical eccentric positions operate in opposite directions, thereby causing the pair of upper and lower crank levers 24 to move in opposite directions via the slider 27. Since the racks 13 reciprocate in opposite directions, both racks 13
Nozzles 1a, 1b with gears 12 driven by
#ψ・1. The adjacent odd-numbered and even-numbered nozzles ln and In-1 alternately face each other or move away from each other.

Therefore, the continuous product of the molded body 14 formed by the nozzles l, lb* In has a planar pattern as shown in FIG. ) Shape and thickness width 1
It becomes possible to produce a product consisting of 4 parts.

In this case, the nozzle 1n is configured as a metal frame that can be inserted into and removed from the mounting hole of the part opened in the above-mentioned cylindrical body 8, and the shape of the extrusion opening in this metal frame is as follows.
The example can be configured into any shape as shown in each of the figures m1 to m6 in FIG. 8, and as a result, the product can be obtained with a cross-sectional shape corresponding to these shapes.

Furthermore, by adjusting the feed rate using the fence conveyor 〇 mentioned above, when increasing the feed rate for the form Po formed in a chevron wave shape, form PI is obtained, and when this feed rate approaches the extrusion speed of the molded object, It is possible to form a sinusoidal waveform as in the form Pl, and to form an arcuate shape as in the form P3 by further slowing down the feed speed.

Example I The mat material used is a compound material containing 100 parts of polymerized vinyl chloride, 50 parts of a plasticizer, 2 parts of a stabilizer, and 0.1 part of a coloring agent.

The nozzle has a gap of 20 mm between adjacent nozzle centers.
Arrange the 4 pieces in a horizontal row on the T-gui.

The nozzle swing angle is 60°.

Die temperature 180'~185°C Die pressure
60kg/c layer 2 Extrusion pressure 180kg/cts2 Conveyor speed? Oc layer/win The strip-shaped molded body extruded from the T die has a resin temperature of 170
Since the temperature is as high as 185°C, the molded product is placed on a horizontal mesh conveyor or belt conveyor and guided into a cooling machine so that the shape of the molded product is not unnecessarily deformed.

A sliding water tank is effective for cooling. That is, by spraying cold water from above and below, the heated resin is cooled down to room temperature.

Each subsequent processing machine including the cooling machine is equipped with a feed roller conveyor, but in order to guide the molded bodies at a constant speed, it is effective to control them with transport rollers E and J.

Since the molded body cooled by water spray contains moisture, the adhesion-resistant moisture is dried by drying fiF with cold air or normal temperature air.

Thermoplastic soft synthetic resin is used as the mat material,
PVC is effective in meeting the requirements for such mats.

In particular, using this as a base material, it is odorless, chemically resistant, has excellent water resistance, is flame retardant, is resistant to organic solvents, has good electrical insulation properties, and can be used to create unique mat hardness. I can do it. In other words, it is effective in creating cushioning properties of the mat.

Bratisol processing is performed to give gloss to the molded mat, improve quality, and strengthen strength and durability.

Platisol processing is performed as a measure to improve quality, and is not particularly necessary for original matte products.

Bratisol exists for each material used, but as is well known, it is effective to use vinyl bratisol when polymerized vinyl chloride is used as the mat material.

The following formulation of vinyl platisol is used.

PVC pesto resin 50 parts plasticizer
42.5 parts filler
5 parts stabilizer 2
Part chilling agent 0.5 part Pigment
In the 0.1 part coating method, a platisol coating film can be formed on the entire mat by uniformly spraying it on the front and back sides of the mat using a sprayer sent from the coating machine G.

The matte coated with bratisol by the coater G is transferred to the drying oven H.

The drying oven H is a screen conveyor or roller conveyor with a heating element inside, and the temperature is 150° to 180°.
Cured with C.

When fusion is complete, it has a glossy finish and also serves as reinforcement for the mesh.

The mat that comes out after being heated to a high temperature in the drying oven H is softened, so it is sent to the cooling chamber I while being held horizontally, where it is heated to room temperature (20° to 25' C
). The mat, which has been cooled to room temperature, is sequentially rolled up by a winding machine and cut into a certain size to be successively manufactured into products.

As a result, a planar space formed by the strip-shaped molded body is a 1:1 square mesh pattern (shape shown in Figures 6 and 7), and the cross section is 2 ms wide and 15 mm high.
You can make a 10mm2 mat with a width of 900+sm and a weight of 5.350kg per square meter.

Example II Same material and same processing steps as Example I, but conveyor speed (pulling speed) for strip shaped bodies 85c+
Set it to s/sin. In addition, the extrusion pressure was 180 kg/cs.
When setting +2, the planar mesh shape of the mat becomes a diamond-shaped shape with a ratio of 1:1.5 (
(see Figure 9, P2), and a mat weighing 4.900 kg per square meter can be obtained.

Example　■ The materials, equipment, molding conditions and steps are also the same as in Example I.

The shape of the nozzle extrusion opening is 2IllI wide and 15m high.
Let it be a rectangle of m (see ml in Figure 8).

Since the surface of the molded mat is flat on each belt surface, the entire mat is completed with a flat surface.

This gives the shoes and feet a flat feel and reduces the stress on the body when walking.

Example 2 The material, equipment, and molding conditions are the same as in the example, and the shape of the nozzle extrusion opening is circular with a diameter of 5 mm (see Fig. 8, m4).

The center of the nozzle and the center gap are formed by 20 layers, a mat width of 900 mm, and a speed of 80 cm per minute.

As a result, a mat having a weight of 3.5θOkg per square meter can be produced.

〔Effect of the invention〕

As described above, according to the method of the present invention, in addition to causing the nozzles arranged in rows on the T-die to move in synchronization and swing, the adjacent nozzles are forcibly driven so that they operate in opposite directions. Since we have adopted a means to do this, the strip-shaped molded bodies extruded from each nozzle meander in a wave-like manner with a constant amplitude, and the adjacent molded bodies are brought into contact and fused at a predetermined interval to form a network. This fusion makes it possible to form a matte shaped body, and this fusion makes the abutting part strong and free from peeling and other problems. By adopting the processing means of 2.

It is relatively easy to change the shape of the mesh pattern to form a unique shape, and by adding a third processing means that changes the shape of the nozzle outlet, the modification of the mesh pattern can be made more diverse. It becomes possible to do so.

According to the method of the present invention, since the meandering of the strip-shaped molded body is performed by forced means using nozzle rocking, it is possible to manufacture a thick mat with a soft synthetic resin material, which improves cushioning properties. In addition to providing an excellent walking feeling, it also increases the brushing effect on the soles of shoes, etc.
It has an excellent ability to wipe away dirt from the soles of shoes, etc., and since the dirt and water that have been wiped off fall to the floor through the mesh-like through holes, there is almost no residue left on the mat surface.
The method of the present invention is extremely effective in practical use as a means for producing this type of floor mat, as it exhibits sufficient mat functionality and the mat itself can be washed with water very easily.

Note that in the mat manufactured by the method of the present invention, one end surface of the strip-shaped molded bodies forming the mesh is laid in contact with the floor surface, so that water that has settled in the mesh can drain into the gap between the floor surface and the end surface of the molded object. However, in order to make this happen more actively, the shapes of several of the extrusion ports spaced apart among the horizontally arranged nozzles may be made to have a shape that is somewhat shorter in the vertical direction. By raising the end surface corresponding to the bottom side of the mat of the strip-shaped molded body extruded from these to some extent higher than that of the other molded bodies, the gap created in this part is made to function as a water drainage groove. It is valid.

[Brief explanation of drawings]

Fig. 1 is a schematic process diagram showing a preferred embodiment of the method of the present invention, Fig. 2 is a plan view of the T-die portion used in the method of the present invention, and Fig. 3 is a longitudinal cross-section of the nozzle structure used in implementing the method of the present invention. A side view, FIG. 4 is a configuration diagram of a molded body based on the nozzle operation, FIG. 5 is a configuration diagram of a nozzle drive mechanism used in carrying out the method of the present invention, and FIG. FIG. 7 is a plan view showing an example, FIG. 7 is a perspective view showing a part of the mat cut away, FIG. 8 is a shape diagram showing the shape of the extrusion opening of the nozzle used in carrying out the method of the present invention, and FIG. FIG. 3 is a diagram of the mesh shape of each mat manufactured by the method. A11Φ fist extrusion @E...T die C-...fence conveyor D...cooler E and JφΦ/transport roller F...φ dryer G...coating machine H...drying furnace...・In the cooling room - fist ``Detailed description of the invention''

Claims (2)

[Claims] (1) In forming a plurality of strip-shaped molded bodies arranged in a row using an extrusion molding machine using a thermoplastic soft synthetic resin as a material, each nozzle arranged in a row in a T-die of the extrusion molding machine is arranged in a row in a direction in which the molded material is extruded. is able to swing freely against the
The swinging directions of adjacent nozzles among these nozzles are regulated so that they are cyclical movements in opposite directions, and each strip-shaped molded body extruded from each nozzle meanders while adjoining molded bodies. a first processing means for continuously forming fused mesh-like elongated bodies at predetermined intervals based on the cycle; a second processing means for adjusting the speed of conveyance of the conveyor to be accelerated or decelerated with respect to the extrusion speed of the strip-shaped molded body; (2) A third system in which the nozzle is of a replaceable cartridge type, and a mesh-like molded body having a different cross-sectional shape of the strip-shaped molded body is formed using various nozzles with different extrusion opening shapes.
The method for manufacturing a floor mat according to claim 1, comprising the treatment means of