JPH06904A - Mat material, its production and production device - Google Patents

Abstract

PURPOSE: To provide a long-size mat material which shows high liquid permeabil ity and also high cushioning properties. CONSTITUTION: This reticular mat material A is formed of a layer of longitudinal materials 1 arranged, spaced from each other and a layer of a plurality of transverse materials 3 which intersect with the longitudinal materials 1 under the layer of the materials 1, insetted in the mortises of the materials 1 and are fusion-bonded together. This mat material A can be simply manufactured by introducing the tip part of the longitudinal material 1 into the annular groove of a first roll and also introducing the transverse material 3 through the parallel groove of a second roll and further, reversing the rolls to each other while both longitudinal and transverse materials 1, 3 are heated. Thus it is possible to obtain the mat material which is laid on the floor without impairing its liquid permeability, and gives high cushioning effect and further, can be manufactured to the optional length.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a mat material, a method for manufacturing the mat material, and a manufacturing apparatus for the mat material. In particular, the present invention relates to a synthetic resin long mat material obtained by heat-sealing a thermoplastic resin wire in a cross beam shape and a manufacturing technique thereof.

[0002]

2. Description of the Related Art Conventionally, a foamed resin sheet having elasticity formed by forming irregularities on both front and back sides has been punched into a predetermined size,
Further, a synthetic resin mat is known in which a large number of through holes for draining water are formed. This product is laid on the floor of a bathroom in a home or on the floor of a factory production line, and is used as a cushioning material or a heat insulating material having an anti-slip effect. Further, a cushioning material for packing made of a foamed resin molded body having no elasticity is also known. On the other hand, there is also known a mat made of a rubber molded product having a large number of vertical grooves formed on the front surface and a large number of horizontal grooves formed on the back surface. This is to intervene between the floor and the floor of a machine such as a press machine that vibrates to have a vibration-proof function.

[0003]

The mat made of the foamed sheet has high cushioning property and heat insulating property, but has insufficient strength, and there is a problem that it is easily broken when a hard object is dropped or rubbed. Also, because the number of through holes per predetermined area is small, when spilling liquid on the surface,
Poor ability to transmit to the back. On the other hand, the rubber mat has high strength but is substantially impermeable to liquid. Moreover, since this product cannot be formed into a long material, it is inconvenient to handle it because it is necessary to arrange a large number of mat pieces so as not to shift each other if they are to be spread on the floor. A first object of the present invention is to solve the problems of the conventional mat, to provide a mat member having high strength, sufficient liquid permeability, and easily formed into a long shape.
Further, it is a technical object of the present invention to provide a method and an apparatus for easily producing such a mat member.

[0004]

The mat member of the present invention comprises a layer composed of a plurality of thermoplastic resin or rubber vertical members arranged in parallel with each other at intervals, and a layer of the vertical members. On one side, in parallel with each other at intervals, a layer of a thermoplastic resin or rubber cross member arranged transversely to the vertical member is provided, the vertical member and the horizontal member, It is characterized in that at least one of them bites into the other party and is welded to each other. In such a mat member, the pitch between the vertical members is 1.5 times the width of the vertical members.
~ 10 times, the pitch between the horizontal members is 3 ~ the width of the horizontal members
10 times the height of the vertical and horizontal members, and the height is 0.3 to
It is preferable to bite at a depth of 0.7 times. Further, a tube in which at least one of the vertical member and the horizontal member is a tube is also used for a specific purpose.

According to the method of manufacturing a mat member of the present invention, a first roll having a plurality of annular grooves for longitudinal members formed in the circumferential direction and a second roll having a plurality of parallel grooves parallel to the axis formed on the surface thereof. The rolls are arranged adjacent to each other in parallel with each other, and the tips of the vertical members made of thermoplastic resin or rubber are inserted into the annular grooves of the first roll, and the parallel grooves of the second roll are made of thermoplastic resin or rubber. The horizontal member is inserted, the leading end of the vertical member and the first horizontal member are heated, and the first roll and the second roll are rotated in the opposite directions in the direction in which the vertical member and the horizontal member are drawn, thereby sequentially The feature is that heated horizontal members are sequentially welded one by one to a row of vertical members. The mat material manufacturing apparatus of the present invention comprises: a first roll having a plurality of annular grooves for longitudinal members formed in the circumferential direction; a second roll having a plurality of parallel grooves formed on the surface parallel to the axis; A frame that rotatably supports the first and second rolls in parallel with each other and adjacently to each other, a heater arranged in proximity to both the first roll and the second roll, and a first roll and a second roll. And a drive system that rotates in the opposite direction and at the same peripheral speed.

[0006]

In the mat member of the present invention, vertical members and horizontal members are three-dimensionally combined. Therefore, for example, when the cross member is placed on the floor with the cross member facing downward, a gap is formed between the vertical member and the floor surface.
The gap is continuous in the lateral direction between the adjacent horizontal members, and is also in communication with the upper part of the mesh mat through the gap between the vertical members. Therefore, even if a liquid such as water or oil is spilled from above, it can be smoothly discharged through the gap between the cross members. Further, as described above, since there is a gap between the vertical member and the floor surface, a portion of the vertical member while being supported by the horizontal member can be bent downward by the amount of the gap. Therefore, the cushioning effect is extremely high even though the foamed sheet is not used.

In the manufacturing method of the present invention (claim 4),
A method of sequentially welding horizontal members one by one to the row of vertical members is adopted while passing the row of long vertical members between the first roll and the second roll. Therefore, the net-like mat having a three-dimensional structure can be manufactured as a long product, that is, without substantially limiting the length. Also, first of all, the ends of the vertical members are first and second.
If it bites between the rolls, it is automatically sent to the welding position as the rolls rotate. Therefore, the operator only has to supply the cross members one after another to the second roll.
It can also be supplied automatically. Moreover, since the first roll and the second roll rotate in synchronization with each other, the horizontal members and the vertical members accurately intersect each other at a predetermined pitch at the contact portion of the first roll and the second roll, and are firmly pressed against each other. . When the horizontal member is pressed against the vertical member, when the rotation of the roll is temporarily stopped, the two members can be firmly pressed against each other during the stop, and they can bite each other (claim 5). Further, if the next vertical member and horizontal member are heated during that time (Claim 5), sufficient heating can be performed, and new horizontal member can be slowly supplied during that period. The manufacturing apparatus (claim 6) of the present invention can efficiently carry out the manufacturing method. Furthermore, in the case of a device having a winding drum, the temperature of the longitudinal members and the cross members decreases by the time it reaches the winding drum, and they are already firmly fixed. Therefore, different layers do not stick to each other.

[0008]

The present invention will be described below with reference to the drawings. FIG. 1 is a perspective view showing an embodiment of a mat member of the present invention,
2 and 3 are sectional views taken along line II-II of FIG. 1 and
III-III sectional view, FIG. 4 is a perspective view showing another embodiment of the mat member of the present invention, and FIGS. 5 and 6 are V of FIG. 4, respectively.
-V line sectional view and VI-VI line sectional view, FIG. 7 is a perspective view showing an embodiment of the manufacturing apparatus of the present invention, FIG. 8 is a side sectional view of the apparatus of FIG. 7, and FIG. 9 is of the apparatus of FIG. FIG. 10 is a perspective view showing a state in which the heater is raised upward, and FIG. 10 is a perspective view of a main part of the apparatus of FIG. The mesh mat material A shown in FIG. 1 has a plurality of rows 2 of vertical members 1 arranged at narrow intervals (pitch) S ₁ and a wide interval (pitch) S ₂ on the back surface side of the columns 2 of the vertical members 1. And a row 4 of cross members 3 arranged in. As shown in FIGS. 2 and 3, the vertical member 1 and the horizontal member 3 are welded to each other so as to bite into each other.

On the surface of each vertical member 1, three rows of ridges 5 extending along the longitudinal direction are formed, and the cross-sectional shape is "E" -shaped as shown in FIG. A large number of wedge-shaped recesses 6 are provided at intervals on each mountain 5, and form a non-slip unevenness as a whole. The vertical member 1 and the horizontal member 3 are
An elastic or flexible thermoplastic resin such as polyvinyl chloride, polyethylene, polypropylene, or a natural or synthetic rubber is extruded to form a long wire, which is further cut into a predetermined length. The peaks 5 on the surface can be formed at the same time when the vertical member 1 is extrusion-molded, and the recesses 6 can be formed immediately after the extrusion molding, for example, by a pressure roll or the like. The concave portion 6 can be formed at the same time when the vertical member 1 and the horizontal member 3 are welded by a manufacturing apparatus described later.

The width W (or diameter) and the height H of the vertical member 1 and the horizontal member 3 can be selected according to the use, but in the case of a floor mat, it is usually about 5 to 20 mm, particularly 7 to 12.
mm is preferable. The pitch S ₁ of the vertical member 1 is 1.
About 5 to 10 times, the pitch S ₂ of the cross member 3 is preferably about 3 to 10 of the diameter. Further, the biting amount (depth) F of the vertical member 1 and the horizontal member 3 is preferably 0.3 to 0.7 times the diameter. This reticulated mat material A can be used as a floor mat having an anti-slip effect by laying it on the floor surface which is wet with water or oil with the vertical member 1 side facing upward. Since the mat member A can be manufactured as a long member that is long in the longitudinal direction of the vertical member 1, as will be described later, it is convenient to lay it on the floor surface of a factory production line. It can also be cut into an appropriate size and used as a drainboard for a bath. In addition, because it has a three-dimensional structure, it has appropriate elasticity. Since it is not a foam material, it has high strength, and since there are many welding points, it is solid overall.

In the reticulated mat member B shown in FIG. 4, both the vertical members 8 and the horizontal members 9 are tubular. Alternatively, only one of them may be tubular. The thickness t of the tube is not particularly limited, but in the case of extrusion molding, the thickness t is, for example, 0.1 to 0.3 times the diameter D. In addition, the vertical member of the tube 8
Even when the transverse members 9 are welded to each other by welding, the respective tubes are deformed inward as shown in FIGS. 5 and 6, so that the tube itself is not broken.
Further, the welded portion 10 of the vertical member 8 and the welded portion 11 of the horizontal member 9 rise in a mountain shape on the inner surface of the tube to narrow the inner diameter, but the liquid conductivity of the tube is secured. Therefore, the reticulated mat member B of FIGS. 4 to 6 can be used, for example, as a heat collecting tube of a solar water heater after being blackened. Alternatively, the mat member B may be rolled into a tubular shape, and the tubes at both ends may be shifted one by one and joined together to form a coiled tube. Furthermore, vertical members 8 and horizontal members 9
Is a hollow tube, the mat material A in FIGS.
The cushioning effect is higher than that of. Therefore,
When the mat material B of 6 is used as a packing cushion material, the function of protecting the product to be packed is higher than that of the mat material A. Examples of the mat member are shown in FIGS. 1 and 4, but the shapes and dimensions of the vertical and horizontal members constituting the mat member,
In particular, the cross-sectional shape is not limited to them. For example, other than those described above, various shapes such as a polygonal shape, a star shape, and an elliptical shape may be adopted.

An apparatus and method for producing the reticulated mat material will be described with reference to FIGS. In the manufacturing apparatus of FIG. 7, reference numeral 21 denotes four columns 21a on the front, rear, left and right
And a beam 21b connecting them. An inclined beam 21c is provided on the side of the frame 21, and on the inclined beam 21c, the first roll 22 and the second roll 23 are adjacent to each other in parallel with each other and are freely rotatable by pillow blocks 22a, 23a. It is supported.

As shown in FIG. 8, the first roll 22 and the second roll 23 are chains or gears 24, 25, 26, 2
7 and the like so that the peripheral speeds are the same and the rotation directions are opposite. In this embodiment, the gears 25 and 26 are interposed, and the pillow block 22a supporting the first roll 22 is positionally adjustable along the inclined beam 21c to adjust the gap between the first roll 22 and the second roll 23. It is configured to do.

As shown in FIG. 9, a motor M is mounted in a cover 28 on the right side of the frame 21, and a worm wheel 30 mounted on a drive shaft of the motor M and a worm wheel connected to the first roll 22. 1st through 31st
The roll 22 is decelerated and driven.

As shown in detail in FIG. 10, the first roll 2
An annular groove 32 into which a large number of vertical members 1 are inserted is formed on the surface of 2 at an equal pitch. On the surface of the second roll 23, a plurality of parallel grooves 33 for supplying the cross member 3 are formed in parallel with the axis at equal pitches. Each of the annular groove 32 and the parallel groove 33 has a depth of about half the diameter of the vertical member 1 to the horizontal member 3 to be inserted. There is usually some gap between the surfaces of the first roll 22 and the second roll 23. However, when the vertical member 1 and the horizontal member 3 have large elasticity, for example, when using a tubular wire, both rolls may be brought into contact with each other. The gap between the rolls is adjusted by adjusting the position of the pillow block 22a for the first roll 22.

As shown in FIGS. 7 and 9, in parallel with the contact line or the proximity line of the first roll 22 and the second roll 23,
A heater 34 for heating the wire is attached. The bracket 35 that supports the heater 34 is preferably configured to be rotatable upward as shown in FIGS. 8 and 9 in order to improve workability when inserting the vertical member 1. As is apparent from FIG. 8, the axis of the second roll 23 is arranged obliquely downward as compared with the axis of the first roll 22, so that the common tangent plane of both rolls 22 and 23 is perpendicular to the vertical line. It is tilted about 45 °. This is for making it easier to see the state in which the horizontal member 3 is in contact with the vertical member 1, and for ensuring a sufficient contact length between the second roll 23 and the manufactured mat member A.

Below the frame 21, a pair of two winding drums 36 and 37 are rotatably provided in parallel with the first roll 22 and the like. These take-up drums 3
Reference numerals 6 and 37 are provided for rolling the mat material A, which is welded in a net shape as shown in FIG. That is, one winding drum 37 rotates freely, but the other winding drum 36 is connected by a chain 38 or the like so as to synchronize with the first roll 22. Incidentally, 39 in FIG. 8 is a sprocket for adjusting the tension of the chain 38.

Behind the first roll 22, the first roll 2
A pair 1 table 40, which is somewhat lower than the surface of 2, is placed horizontally. The first table 40 is for aligning and placing a large number of vertical members 1 to be supplied to the first roll 22. Similarly, when the tip of the second roll 23 is slightly lowered from the upper portion of the second roll 23,
The table 41 is arranged with some inclination. The second table 41 is for placing the cross member 3 to be supplied to the second roll 23. The second table 41
By appropriately selecting the inclination angle of the second roller 23 so that the leading edge is almost in contact with the surface of the second roller 23, the parallel grooves 33 of the second roller 23 automatically spread the horizontal members 3 one by one. .

Next, a method of manufacturing a mat member using the apparatus constructed as described above will be described. First, a vertical die 1 is manufactured by setting a predetermined die in an extrusion molding machine.
At that time, the vertical member 1 is pulled while being straightened by a take-up machine, and cut by a cutter according to the length of the mat to be manufactured. In that case, it is preferable that the vertical member 1 be extruded while being sequentially arranged along one side of the first table 40. The cross member 3 is extruded in advance and cut into pieces according to the width of the mat with a cutter, and the cut pieces are housed in a case 55 shown in FIG. Next, the vertical member 1
The entire table 40 is aligned, and the tip ends of the tables are fitted into the annular groove 32 of the first roll 22, and are caught between the first roll 22 and the second roll 23. Furthermore, the horizontal member 3 is second
After being aligned on the table 41, they are inserted into the parallel grooves 33 appearing on the surface of the second roll 23. This completes the preparation.

Next, the heater 34 is lowered and the power source is turned on to heat the tip portion of the vertical member 1 and the first horizontal member 3. After that, the drive motor M of the first roll 22 is rotated by one pitch of the parallel groove 33 and stopped. Then, the first cross member that has been heated enters the contact portion between the first roll 22 and the second roll 23, is firmly pressed against the row of the vertical members, and is heat-sealed. The operator inserts a new cross member from the second table 41 into the empty parallel groove 33 appearing from below the second table 41 during the stop. Further, during the stop, the heater 32 heats predetermined portions of the horizontal member and the vertical member to be welded next. After the predetermined stop time has elapsed, the first roll 22 and the second roll 23 are further rotated by one pitch. As a result, a large number of vertical members 1 are wound by one pitch, and the next horizontal member 3 is pressed against the row of the vertical members 1. The vertical members 1 may be inserted into all the annular grooves 32 of the first roll 22, or may be inserted every other row or at intervals of more than that. The same applies when the horizontal member 3 is inserted into the parallel groove 33 of the second roll 23. In this case, the second roll 23 is stopped by picking the parallel groove 33 containing the cross member 3. As a result, various mat materials A having different pitches of the vertical members 1 and the horizontal members 3 can be manufactured.

In this way, while one set of the first roll 22 and the second roll 23 is rotationally driven in the opposite direction, the horizontal members 3 are fused one by one to the vertical member 1 in a cross shape, and the reticulated mat member A is formed. Is manufactured. The produced mat member A hangs downward from between the first roll 22 and the second roll 23 and comes out. In that case, the reticulated mat A can be pulled out to the floor surface as it is, but in the apparatus of FIG. 7, it is rolled on a pair of drums that rotate intermittently in synchronization with both rolls,
It is wound into a multilayer coil. Since the temperature of the reticulated mat A decreases when it moves downward, there is no risk of sticking between the layers even when wound in a multilayer coil.

In the above-described embodiment, the horizontal members are inserted one by one into the parallel groove 33 of the second roll 23, but they may be automatically supplied by using an intermittent feeder or the like. Good. Further, if the manufacturing speed may be slow, it is possible to manufacture while continuously rotating the first roll 22, the second roll 23 and the like. Although the vertical member and the horizontal member each have one layer in the above-mentioned embodiment, the mesh mat is further turned inside out and passed through the first roll, and the horizontal member or another mesh mat is welded while being supplied by the second roll. The material and the horizontal material may be alternately stacked to form a three-layer, four-layer, or further multi-layer mat. Such a multilayer mat is suitable for a heat collecting tube for a water heater.

[0023]

According to the reticulated mat of the present invention (claim 1), the vertical members and the horizontal members are three-dimensionally combined and each has a gap, so that the cushioning effect is obtained without using a foam material. The liquid permeability is high. Furthermore, when either the vertical member or the horizontal member is a hollow tube (claim 3), the cushioning effect is further enhanced. You can also use it to pass liquid through the tube. According to the manufacturing method of the present invention (claim 4), since the vertical member is sequentially fed between the first roll 22 and the second roll 23, there is no limitation on the length of the mesh mat to be manufactured. In addition, the vertical members and the horizontal members can be combined at an accurate pitch and firmly welded. Therefore, a long mat can be continuously and efficiently manufactured. The manufacturing apparatus (claim 6) of the present invention can continuously and efficiently manufacture the reticulated mat.

[Brief description of drawings]

FIG. 1 is a perspective view showing an embodiment of a mat member of the present invention.

FIG. 2 is a sectional view taken along line II-II in FIG.

3 is a sectional view taken along line III-III in FIG.

FIG. 4 is a perspective view showing another embodiment of the mat member of the present invention.

5 is a sectional view taken along line VV of FIG.

6 is a sectional view taken along line VI-VI of FIG.

FIG. 7 is a perspective view showing an embodiment of the manufacturing apparatus of the present invention.

FIG. 8 is a side sectional view of the device of FIG.

9 is a perspective view showing a state where a heater of the apparatus of FIG. 7 is raised upward.

10 is a perspective view of an essential part of the apparatus shown in FIG.

[Explanation of symbols]

 A mat material B mat material 1 vertical material 3 horizontal material 8 vertical material 9 horizontal material 21 frame 22 first roll 23 second roll M motor 30 worm 31 worm wheel 32 annular groove 33 parallel groove 34 heater

Claims (6)

[Claims] 1. A layer composed of a plurality of vertical members made of thermoplastic resin or rubber arranged in parallel with each other at intervals, and one layer of the vertical members is parallel to each other at intervals. And a layer of a transverse member made of a thermoplastic resin or a rubber which is arranged to intersect with the vertical member, and at least one of the vertical member and the horizontal member bites into the opponent. A net-like mat material that is welded to each other in the state. 2. The pitch between the vertical members is 1.5 of the width of the vertical members.
~ 10 times, the pitch between the horizontal members is 3 ~ the width of the horizontal members
10 times, and the vertical and horizontal members are 0.3 mm higher than each other.
The mat member according to claim 1, wherein the mat member penetrates at a depth of ~ 0.7 times. 3. The mat member according to claim 1, wherein at least one of the vertical member and the horizontal member is a tube. 4. A first roll having a plurality of annular grooves for a vertical member formed in the circumferential direction and a second roll having a plurality of parallel grooves parallel to the axis formed on the surface thereof are adjacent to each other in parallel. , And insert the tip of the vertical member made of thermoplastic resin or rubber into the annular groove of the first roll, and the horizontal member made of thermoplastic resin or rubber into the parallel groove of the second roll. The tip end of the material and the first cross member are heated, and the first roll and the second roll are rotated in the opposite direction in the direction in which the vertical member and the cross member are pulled in, thereby sequentially heating the cross members of the vertical member. A method of manufacturing a mat material by sequentially welding one by one in rows. 5. Each time the horizontal member comes into contact with the vertical member, the rotation of both rolls is temporarily stopped to firmly press the already heated vertical member and the horizontal member, and while the horizontal member is stopped. 5. The method according to claim 4, wherein the next horizontal member and a portion of the vertical member corresponding to the horizontal member are heated, and a new horizontal member is supplied to the next empty parallel groove. 6. A first roll having a plurality of annular grooves for longitudinal members formed in the circumferential direction, a second roll having a plurality of parallel grooves formed on its surface parallel to the axis, and first and second rolls. A frame that rotatably supports the rolls in parallel with each other and adjacently to each other, a heater that is arranged in proximity to both the first roll and the second roll, and a reverse roll of the first roll and the second roll. And a drive system that is rotationally driven in the same direction at the same peripheral speed.