JPH03228711A - Mat and manufacture thereof - Google Patents

Abstract

PURPOSE:To simplify the manufacturing process, improve the working efficiency, and prevent the deterioration of the working environment by using a mold having the unevenness which is reverse to the unevenness to be formed on a mat and arranging a sheet member as adhesion medium which possesses the heat melting performance between a basic cloth and a covering cloth. CONSTITUTION:A surface plate 6 which is used also as high frequency welding electrode has a mold 61 having the unevenness which is reverse to the unevenness which is to be formed on the surface of a mat, on the upper surface. The covering cloth 2 such as pile cloth is laid along the mold 61. The rod-shaped sponge members 5,... having a circular section are embedded to the part corresponding to the recessed part 61a of the mold 61 on the covering cloth 2. A sheet member 7 made of polyvinylchloride which possesses the heat melting performance is placed so as to cover the rod-shaped sponge members 5,... and the covering cloth 2, and a basic cloth 2a made of the tough canvas, jute ramie, etc., is superposed on the sheet member 7. Then, the sheet member 7 is molten by applying the high frequency waves between a movable plate and the surface plate 6, and poured into the stripes of the covering cloth 2 and the basic cloth 1 and further into the rod-shaped sponge members 5,..., and these members are fused to finish a mat.

Description

DETAILED DESCRIPTION OF THE INVENTION [Industrial Application Field] The present invention relates to a rug having corrugated irregularities formed on one surface thereof, and a method for manufacturing the same.

[Prior Art] Rugs such as cushions, seat backs, and futon mats are used to relieve physical fatigue, but if your body is in contact with a flat rug for a long time, it can cause damage to your body. The weight of the rug reduces its breathability and traps moisture, making it uncomfortable to lay on.There are also problems in that body parts that are in contact with the rug continue to be uniformly compressed, leading to fatigue. To solve this problem, a rug is created by arranging rod-shaped core materials such as sponge material at regular intervals inside the rug to form wavy irregularities on the surface.The recesses that do not come into contact with the body allow for ventilation and improve the comfort of the rug. A rug has been devised that uses convex parts to gently stimulate pressure points on the human body, improve facial alignment, alleviate fatigue, and provide a feeling of exhilaration.

The conventional manufacturing method for this rug is to apply adhesive to the entire surface of a base fabric such as canvas, and then adjust the positions of the core materials so that they are parallel to each other at regular intervals on the adhesive-applied surface. The shins are arranged and adhered to the base fabric, and then the core material is wrapped in the covering fabric, and the covering fabric is glued and fixed to the base fabric between the core materials with the exposed surface of the adhesive to create a wavy pattern on the surface of the rug. After forming the unevenness, finish the surrounding area with piping cloth, etc.

[Problem to be solved by the invention]

The conventional method described above requires a step of applying adhesive to the base fabric, and when arranging the core materials on the base fabric coated with adhesive, the core materials are arranged at regular intervals and in parallel. There was a problem in that each process required time and effort, resulting in low work efficiency.

In addition, there was a problem that the working environment was poor because the adhesive used in the adhesive volatilized into the air in the workplace.

The present invention has been made to solve these problems, and uses a mold having concavities and convexities opposite to those to be formed on the rug, and also uses a mold to prevent heat between the base fabric and the covering fabric. The purpose of the present invention is to provide a method for manufacturing a rug, which has a simple manufacturing process, high work efficiency, and prevents deterioration of the working environment by arranging a sheet material having meltability as an adhesive medium, and a rug manufactured by the method. shall be.

[Means to solve the problem]

The rug of the present invention is a rug in which rod-shaped core materials are arranged in strips at predetermined intervals on a base fabric, and the base fabric and core material are covered with a covering fabric to form unevenness. A heat-melting sheet material disposed between the fabric and the fabric is heated and melted to fuse at least the covering fabric and the base fabric.

In addition, in the method for manufacturing a rug of the present invention, a covering fabric is laid along a mold having concavities and convexities opposite to those to be formed, and a core material is placed in a portion of the covering fabric that corresponds to the concave portion of the mold. Then, a base fabric is layered on the core material and the covering fabric. At that time, a heat-meltable sheet material is layered as an adhesive medium after the covering fabric is laid down or the core material is placed, and the core material and the base fabric are layered. It is characterized by fusing cloth.

[Effect]

The rug of the present invention has at least a rod-shaped core material arranged in a strip shape at a predetermined interval, and a covering fabric between the core material, which is a heat-fusible sheet sandwiched between the covering fabric and a base fabric. By heating and melting the material, it is adhered to the base fabric and the core material is fixed. When the uneven surface of the rug is placed in contact with the body, the concave portions improve the ventilation of the rug, and the convex portions moderately stimulate the body to alleviate physical fatigue.

In addition, in the method for manufacturing a rug of the present invention, a covering fabric is laid along a mold having concavities and convexities opposite to those to be formed, and a core material is placed in a portion of the covering fabric that corresponds to the concave portion of the mold. Then, a base fabric is layered on the core material and the covering fabric, and at that time, a sheet material with heat-melting properties is used as an adhesive medium after the covering fabric is laid down, or after the core material is placed, and this sheet material is used as an adhesive medium. It is characterized by being heated and melted, soaking into the covering fabric, core material, and base fabric, and then solidifying to fuse the covering fabric, core material, and base fabric.

〔Example〕

Hereinafter, the present invention will be explained based on drawings showing embodiments thereof.

FIG. 1 is a plan view of the mat according to the present invention, FIG. 2 is a left side view thereof, and FIG. 3 is a partially enlarged sectional view of the first IUI-I line. In the figure, reference numeral 1 denotes a substantially rectangular base fabric made of canvas, jute linen, etc., and the base fabric 1 is covered with a covering fabric 2 such as breathable pile fabric. In the short side direction of the mat, rod-shaped sponge material 5゜5, etc., which will be described later, is built in to make it approximately 2 cI wide.
The convex portions 21, 2L, . ... and each convex portion 21.21... recessed portion 22.2 formed between them.
2. ... forms wavy irregularities on the mat.

A folding groove 23 is formed in the longitudinal center of the mat, extending in the short side direction across the corrugated unevenness, and the mat is symmetrical with the folding groove 23 as a boundary, and is foldable. An appropriate width of the upper part of the mat is flat without any unevenness, and hook-and-loop fasteners 4.4 are arranged at symmetrical positions with the folding part 23 as the center. Four circumferences of the base fabric 1 and the covering fabric 2 are finished with a piping fabric 3. The mat of this embodiment can be connected to other cloaks that have hook-and-loop fasteners at the positions corresponding to these hook-and-loop fasteners 4.4, that is, on the back side, and by connecting a plurality of cloaks, for example, It is possible to construct a large cloak such as

As is clear from the cross-sectional view in Figure 3, the inside of the cloak is as follows:
A rod-shaped sponge material 5 with a circular cross section is placed between the covering fabric 2 and the base fabric 1.
5. ... are arranged in parallel at intervals of approximately 1.5 cm. The covering cloth 2 is made of a rod-shaped sponge material 5.5 which is a core material. . . . to wrap around the rod-shaped sponge material 5, 5. The rod-shaped sponge material 5,5.・
... is fixed, and wavy irregularities are formed on the mat.

Next, the method for manufacturing a mat according to the present invention (hereinafter referred to as the method of the present invention) will be explained. FIG. 4 is a schematic diagram showing the manufacturing process.

The surface plate 6, which is made of a conductive material such as aluminum and which also serves as a high-frequency welding electrode, has a mold 61 formed on its upper surface with concavities and convexities opposite to those to be formed on the mat surface. A covering fabric 2 such as pile fabric is laid along the mold 61 (FIG. 4(a)). A rod-shaped sponge material 5,5. ... (Fig. 4 (b)
)), the rod-shaped sponge material 5.5°... and the covering cloth 2 are covered with a sheet material 7 made of heat-melting polyvinyl chloride, etc., and on the sheet material 7, a stiff canvas or jute material is placed. A base fabric 2a made of linen or the like is laid on top of the other (FIG. 4(C)).

Next, a movable plate (not shown), which is rectangular with a flat bottom surface, made of a conductive material such as aluminum, and which also serves as a high-frequency welding electrode, is placed above the surface plate 6, and the movable plate and the surface plate 6 are connected to each other. The sheet material 7 is melted by applying high frequency waves between the weaves of the covering fabric 2 and the base fabric 1 and the rod-shaped sponge materials 5, 5. . . . Soak into the covering cloth 2 and rod-shaped sponge material 5.5. ... and the base fabric 1 are fused together (Fig. 4(d)).

Finally, attach the hook and loop fastener 4.4 to the flat part of the top of the mat.
sew, and pipe 3 around the 4 circumferences of base fabric 1 and covering fabric 2.
I'll finish it off.

In this embodiment, a manufacturing method in which a high frequency is applied between the movable platen and the surface plate 6 has been described, but it is also possible to incorporate a heater in either the surface plate 6 or the movable platen, or both the surface plate 6 and the movable platen. It is also possible to perform high frequency welding and heat with a heater.

Furthermore, although the manufacturing method using high-frequency welding has been described in this embodiment, it is also possible to heat the sheet material 7 using only a heater built into either the surface plate 6 or the movable plate, or both the surface plate 6 and the movable plate. It is possible.

Further, in this embodiment, polyvinyl chloride is used as an example of the heat-fusible sheet material 7, but the material is not limited to this.

In addition, in this embodiment, a manufacturing method has been described in which the sheet material 7 having heat-melting properties is stacked after the rod-shaped sponge materials 5, 5°... are placed in the portion corresponding to the recess 61a.
After laying the covering fabric 2 along the line 1, the sheet material 7 is overlapped, and then rod-shaped sponge materials 5, 5°... are placed in the portion corresponding to the recess 61a, and the covering fabric, core material, and base fabric are combined. It is also possible to bond them together, and the same effect as in this example can be obtained.

Further, in this embodiment, the cross-sectional shape of the rod-shaped sponge material 5 is circular, but it may be square, polygonal, or the like.

Further, in this embodiment, the core material is a sponge material, but it is not limited to this, and the core material may be made by bundling fibrous materials.

〔Effect of the invention〕

As described above, in the method of the present invention, the core materials can be arranged at regular intervals and parallel to each other by simply placing the core materials in the recesses of the mold having the recesses and recesses opposite to those to be formed on the rug. By simply heating and melting the sandwiched heat-melting sheet materials, the covering fabric wraps around the core material and is fused to the base fabric, thereby fixing the core material, which simplifies the process and improves work efficiency. It has the excellent effect of preventing deterioration of the working environment without volatilization.

[Brief explanation of drawings]

FIG. 1 is a plan view of a futon mattress according to the present invention, and FIG.
The figure is a left side view, FIG. 3 is an enlarged sectional view taken along the line ■■ in FIG. 1, and FIG. 4 is a schematic diagram showing the manufacturing process of the rug. ■... Base fabric 2... Covering fabric 5... Rod-shaped sponge material 6... Surface plate 7... Sheet material 21... Convex portion 2
2... Recessed part 61... Type 61a... Recessed part

Claims (1)

[Claims] 1. Rod-shaped core materials are arranged in strips at predetermined intervals on the base fabric,
In a rug in which a base fabric and a core material are covered with a covering fabric to form irregularities, at least the covering fabric and the base fabric are A rug characterized by being fused together. 2. In the method for manufacturing a rug according to claim 1, a covering fabric is laid along a mold having concavities and convexities opposite to those to be formed, and a core is placed in a portion of the covering fabric corresponding to the concave part of the mold. cover the core material and the covering material with a sheet material having heat-melting properties, overlap the base material on the sheet material, and heat the sheet material to fuse the covering material and the core material with the base material. A method for producing a rug, characterized by: 3. Laying a covering fabric along a mold formed with unevenness opposite to the unevenness to be formed in the method for manufacturing a rug according to claim 1, and overlaying a sheet material having heat-fusible properties on the covering fabric, A core material is arranged on the sheet material in a portion corresponding to the concave part of the mold, a base fabric is placed on the core material, and the sheet material is heated to fuse the covering fabric, the core material, and the base fabric. A method of manufacturing a rug.