JPH11332725A - Resin pipe-arrayed mat - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a resin pipe-arrayed mat usable even at a watering place by thermally melt-sticking many hot-melt resin pipes arranged at substantially equal intervals to flexible foundation cloth with thermal melt-sticking on an end face. SOLUTION: Pipes 3 of the same height arranged at equal intervals by nines in length and width are determined for one group and a total of twelve groups are arrayed on a resin net 1. The outer periphery of the resin net 1 is fringed with cloth 6, an injury by a net end edge is prevented and frays are prevented. As a result, since drainage from a front face to a rear face is excellent, water is not stayed on the front face and also the feet 2 touch upper ends of the pipes 3 so that the feet 2 are bitten, a possibility that the feet 2 slip by the mat is eliminated. The pipes 3 arrayed at prescribed intervals are opposed to the resin net 1 from an orthogonally crossed direction by two sheets of supporting frames, an end face is made a molten state by a heating plate, the end face is thermally melt-stuck to the resin net 1 and this mat is manufactured.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a resin pipe arrangement mat which can be used as a rug, a cushion, a bedding mat, etc. having a good touch.

[0002]

2. Description of the Related Art Rug products such as rugs made of rush (so-called goza), cushions having a cover woven from rush, and bed mats have been popular. This is because the woven rush gives a moderate irritation to the skin, and the air permeability created by the crevices invites a cool feeling especially in summer. In the case of a cushion or a bed mat, it is manufactured by covering a cushion material having elasticity with a rush cover woven in the same manner as a tatami mat.

[0003] As a material that gives an appropriate stimulus to the touched skin, there is a resin mat in which a large number of grooves or projections are integrally formed, such as the surface of a health sandal. Above all,
In these healthy sandals, grooves or protrusions are preferred as stimulating acupoints. Such health sandals do not have air permeability like the cushions and bedding mats having the rush cover described above, but a gap is formed between the grooves or projections and the skin, so that a relatively cool feeling can be brought out. . An example of the same resin-integrated molded product is artificial turf. This artificial turf has a structure in which countless resin mustaches are drawn out of a resin base cloth, and is widely used in baseball stadiums, underlays of terraces of ordinary houses, and in water places (bathrooms and pools).

[0004]

The rush product has a drawback of fading like a general tatami mat. In addition, since the rug and the grass cover are thin, the grass is crushed with time, and the tactile sensation decreases. In addition, in cushions, bedding mats and the like, the cushioning material inside may be crushed and the tactile sensation of the rush cover may not be sufficiently exhibited. Naturally, it is not expected to be used in water.

[0005] In the resin mat in which the grooves or projections are integrally formed, if the grooves or projections deteriorate over time, excessive frictional force is exerted, or conversely, the resin mat is cracked and the tactile sensation of the grooves or projections decreases. There is a problem. In particular, water drops reduced the frictional force when stepped on with wet feet, and there was a risk of slipping on the feet. Of these, artificial turf is the only product that can be used in water. However, due to manufacturing problems, the resin whiskers are generally substantially uniform with respect to the resin base cloth, and it has been difficult to partially change the length or color-code in particular.

[0006] Therefore, as in rush products, resin mats or artificial turf having a large number of grooves or projections, a good tactile sensation giving an appropriate stimulus can be obtained, and the versatility is wide and the design is excellent. However, we decided to continue our study to develop a mat that can be used especially in water.

[0007]

As a result of the examination, the developed thing is that a large number of heat-fusible resin pipes arranged at substantially equal intervals on a heat-fusible flexible base fabric at the end face. This is a resin pipe array mat that is thermally welded. In this mat, the flexible base cloth is preferably a resin net. Alternatively, a mat having a configuration in which both end surfaces of the heat-fusible resin pipe are heat-welded to two flexible base cloths may be used. In this case, a mat having a multilayer structure may be formed by further adding a flexible base cloth.

In the mat of the present invention, pipes arranged on a flexible base cloth at substantially equal intervals can be either (1) directly touching the skin or (2) touching the skin via the flexible base cloth. Gives moderate stimulation.
As a whole, many pipes press the skin at once,
The individual pipes do not cut into the skin, but rather stimulate moderately and provide a good feel. The flexible base fabric has a function of holding a large number of pipes together to prevent separation, and a function of intervening between the pipes and the skin to relieve irritation as described above.

The pipe can be appropriately selected according to the purpose, regardless of the type of resin, as long as the pipe has heat welding properties. For example, there are polyethylene, polypropylene, polyester, and nylon. Usually, since the pipe is manufactured by stretching, the amount of raw material is smaller than that of artificial turf or the like integrally molded with a resin by an injection method. Further, the pipe obtained by stretching has improved strength and elasticity, and has sufficient mechanical properties as a strength member of the mat of the present invention. The flexible base cloth is preferably made of a resin having the same heat-sealing property so as to heat-weld the pipe at the end face, and is preferably a sheet-shaped one having at least an opening for the purpose of securing air permeability as a mat. From this viewpoint, a resin net is most suitable. The size of the mesh may be determined so that a sufficient connection between the heat welded pipe and the resin net can be obtained.

The diameter and height of the pipe are free. The diameter is preferably in the range of 0.1 to 2.0 cm, preferably 0.3 to 1.5 cm, and the height is preferably in the range of 0.3 to 10.0 cm, preferably 0.5 to 7.0 cm. Polyethylene pipes have a certain degree of flexibility and exhibit elasticity when raised. Not only pipes having the same shape but also pipes having different diameters may be arranged, or they may be arranged at different heights so that the copying surface connecting the ends of the pipes has undulations. The pipes may be colored, and by arranging the pipes of a plurality of colors, a mat having excellent design can be produced. A large number of pipes arranged at substantially equal intervals form a kind of honeycomb structure, and the mat has sufficient structural strength against a vertical load. When attention is paid to the improvement of the structural strength, for example, it is conceivable to arrange pipes having different diameters concentrically.

[0011] When a pipe is thermally welded to a resin net, a mat having high air permeability and water permeability and achieving complete isolation between the back surface and the front surface can be produced. For this reason,
The mat of the present invention can be used in a water place. If the flexible sheet as well as the pipe is non-water-absorbing, the resulting mat can be washed with water and exhibits high quick-drying properties. When the pipe is sandwiched between two flexible base cloths, it can be used as a cushion or a bed mat with both flexible base cloths as the front and back surfaces, respectively. In this case, compared to a mat in which one end surface is welded to one flexible base cloth, the pipe is harder to separate and the durability is improved. Furthermore, if it is made into a laminated structure, it will prevent buckling and tilting of the pipe, while maintaining the structural strength as a mat,
The thickness of the mat can be increased.

[0012]

Embodiments of the present invention will be described below with reference to the drawings. FIG. 1 is a perspective view showing a mat (first example) composed of one resin net 1, FIG. 2 is a partial side view of the first example mat, and FIG. FIG. 4 is a partially enlarged side view showing the state of the pipes 3, 4, and 5 particularly in the case of KATO.

In the first example, as shown in FIG. 1, a total of 12 groups are arranged on the resin net 1 as a group of pipes 3 of the same height arranged at equal intervals of 9 pieces in length and width. The outer periphery of the resin net 1 is trimmed with a cloth 6 to prevent injuries due to the edge of the net and at the same time prevent fraying. Of the whole
In FIG. 1, pipes 7 of different colors are used for the left rear and the right front.
Are arranged side by side to form a skewed line to enhance the design. This first example assumes a mat to be laid at the entrance of the bathroom, etc. As can be seen from FIG. 2, the drainage from the front side to the back side is good, so that water does not accumulate on the surface and the top of the pipe 3 The foot 2 touches so that the foot bites into the mat, and there is no danger of slipping the foot on the mat. The mat equivalent to the first example can also be used as a door mat for the purpose of soil removal. In this case, the upper end of the pipe 3 or the resin net scrapes off the soil stuck to the shoe sole.

In the mat, as shown in FIG. 2, the pipe 3 bites into the skin of the foot 2 and gives a moderate stimulus. At this time, when the foot 2 is advanced, the pipe 3 that has penetrated the skin is likely to tilt as the foot 2 advances. However, as shown in FIG. 3, the front pipe 4 tilts in the opposite direction to the pipe 3 which tilts in accordance with the advance of the foot 2 to support the foot 2 sequentially, and the rear pipe 5 Since the tilting pipe 3 is pulled through the resin net 1, it does not tilt as a whole. In addition, the mat of the present invention forms a kind of honeycomb structure with a large number of the arranged pipes 3 and exhibits a strong structural strength against a vertical load, so that the pipes 3 do not actually collapse (buckle). For this reason, the present invention can be used also as a door mat in which the treading pressure becomes large.

FIG. 4 is a perspective view showing a production line for the mat of the first example, and FIGS.
FIG. 5 is a view taken in the direction of the arrow A. FIG. 5 shows a stage where the heating plate 8 is lowered between the sent resin net 1 and the pipe 3, and FIG. Stage, FIG. 7
8 is a stage in which the heating plate 8 is retracted upward, FIG. 8 is a stage in which the end surface of the pipe 3 which has been melted is pressed against the resin net 1,
9 shows a stage in which the cutter 10 is lowered between the support frames 9, 9 to cut the pipe 3, and FIG. 10 shows a stage in which the remaining pipes 3 together with the support frames 9, 9 are retracted.

The mat shown in the first example can be made on the production line shown in FIG. First, the resin net 1 is sequentially sent out from the roll 11 on the far side in FIG. Pipes 3 arranged at predetermined intervals by two support frames 9, 9 are opposed to the resin net 1 sent out in this manner from the orthogonal direction (FIG. 5). The pipe 3 has a heating plate 8 lowered from above.
Then, the end face is melted (FIG. 6), the heating plate 8 is evacuated upward (FIG. 7), and then extruded, and the end face is thermally welded to the resin net 1 (FIG. 8). After welding, the cutter 10 is lowered between the support frames 9 and 9 to cut the pipe 3 (FIG. 9), and the resin net 1 is sent forward by the length of the product to cut the area where the pipe 3 is welded. The separation is complete (Fig. 10). If the width and the final separation length of the resin net 1 sent out from the roll 11 are previously set to the same width as the product, cutting work is not required. If necessary, the product is obtained by edging with a cloth 6 as shown in FIG.

FIG. 11 shows a pipe 3 connected to two resin nets 1, 1.
FIG. 12 is a partial side view corresponding to FIG. 2 of a mat having a sandwich structure (second example). FIGS. 12 and 13 show the welding of the second resin net 1 and the pipe 3 in the production line of the mat of the second example. FIG. The mat of the second example is obtained by welding a second resin mat 1 to the upper end of the pipe 3 opened by the mat of the first example. In the mat of the second example, the skin does not directly touch the end of the pipe 3 and the irritation is reduced. Further, in the second example, as a result of the pipe 3 being sandwiched between the two resin nets 1, 1, the integrity of the pipe 3 is further emphasized, and a mat that is stronger and less crushable than the first example is obtained.

FIGS. 14 to 18 are partial side views corresponding to FIG. 2 showing an example of the combination of the resin net 1 or the apertured resin sheet 12 and the pipe 3 in the mat of the present invention.
3 is a mat in which two layers are arranged at the same position, FIG.
16 is a mat in which the positions are shifted in two layers, FIG. 16 is a mat in which pipes 3 and 13 having different diameters are arranged in two layers, and FIG. 17 is equivalent to a first example in which the pipes 3 are arranged on a perforated resin sheet 12. FIG. 18 shows a two-layer mat in which pipes 3 and 13 having different diameters are arranged on a perforated resin sheet 12 and resin nets 1 and 1, respectively.

The mat of the present invention can have a height of up to about 10 cm, depending on the material and diameter of the pipe, so that only one layer of pipe is sufficient to constitute almost any mat. However, a very long pipe, except for one with a certain degree of flexibility, has concerns about buckling, etc.
In order to increase the structural strength, a multilayer structure is preferable as shown in FIG. In this case, if the pipes 3 in each layer have the same shape, the pipes 3 arranged in the same position strongly sandwich the resin net of the middle layer at the edges of each other, as shown in FIG. 15, for example. In this manner, the arrangement positions of the pipes 3, 3 may be shifted, or the pipes 3, 13 having different diameters may be arranged as shown in FIG.

A flexible base cloth that closes the end of the pipe is not preferable because it accumulates dust and water. However, as shown in FIG. 17, an opening having a large number of holes 14 communicating with the pipe 3 is provided. The resin sheet 12 and the like can be applied to the present invention. Naturally, even in a multilayer structure, as shown in FIG.
12 can be used. The apertured resin sheet has a flatness as compared with the resin net, and the adhesion to the floor surface or the like is increased by a process of exerting a frictional force on the back surface or by separately attaching a sheet. For example, when a perforated resin sheet 12 with improved frictional force is employed on the bottom surface as in the mat of FIG. 18, a mat that does not slip can be formed.

Finally, some examples of products to which the mat of the present invention is applied will be described. FIG. 19 shows a mat of the second example (FIG. 11).
FIG. 20 is a partially broken perspective view of a flip flop (third example) to which the mat of the second example is applied,
FIG. 21 shows a bed mat using a three-layer mat (fourth example).
Partially cutaway perspective view (the middle and lower layers of the net are not shown),
FIG. 22 is a partially cutaway perspective view of a bed mat (fifth example) to which a one-layer mat using a flexible pipe is applied (the lower layer net display is omitted), and FIG. FIG. 11 is a partially cutaway perspective view of a cushion (fifth example) to which a mat having a two-layer structure is applied in combination with FIG. Each of the exemplified products can be basically manufactured in a similar manner on the above-described manufacturing line.

The mat of the second example is similar in appearance to the mat of the first example, as shown in FIG.
In the example, the upper layer of resin net 1
Is different. As described, pipe 3
The stimulating feeling that the end bites directly into the skin is reduced, but the integrity of the pipe 3 is enhanced and the structural strength is further improved. As for the use, a mat in a water place (bathroom or entrance to a pool) is suitable as in the first example.

An example of applying the mat of the second example is shown in FIG.
FIG. 20 shows a flip-flop as a third example. In the third example, the mat shown in the second example is cut in accordance with the shape of the foot, and a rubber frame 15 for giving tension by pulling the resin net 1 outward is attached to the outer periphery, and a band 16 for hanging on the instep of the foot is attached. It has the same appearance as conventional flip flops. This flip flop sandals have a good tactile feel that gives a moderate stimulus to the sole, with a pipe 17 that is higher than the pipe 3 arranged in the center corresponding to the arch, especially for use in water places. Suitable and, above all, structurally very light. Further, the material cost and the manufacturing cost are extremely low, and the product is disposable.

In the bedding mat of the fourth example, as shown in FIG. 21, pipes 3, 17, and 18 having different heights are arranged on the surface layer so that the profiling surface is corrugated. The arrangement of the pipes 3, 17 and 18 having different heights in this manner causes the pipe 18 which is particularly protruding to tilt against a load from above. In the fourth example, the resin net 1 is welded to the surface layer. And pipe 3,1
Care is taken to prevent the pipes 3, 17, 18 from tipping due to the mutual pulling of 7,18. Also, while realizing a sufficient thickness as a bedding mat, in order to counter vertical load (in this case, the weight of the user using the bedding mat), a large diameter pipe 13 is arranged in the middle layer, The lower layer adopts a multilayer structure in which small diameter pipes 3 are arranged.

For such a bed mat, as shown in FIG. 22, a flexible pipe having a height of about 6.0 to 7.0 cm is used.
Even if a one-layer mat using 21 (for example, a polyethylene pipe) is applied, a product that achieves both a sufficient elasticity and a tactile sensation that provides appropriate stimulation can be obtained. The elasticity of such a flexible pipe is preferable when the present invention is applied to a cushion or a bedclothes mat where elasticity is desired as in the fifth example. It is useful when scraping off.

As shown in FIG. 23, the cushion of the sixth example has, as a lower layer, a resin sheet 12 made of a foamed resin capable of providing a feeling of elasticity, and three concentric pipes 19, 20, 13 in the middle layer. They are arranged to achieve both sufficient height and structural strength. In the upper layer that touches a person, pipes 3 having a small diameter are arranged in order to achieve a tactile sensation for obtaining an appropriate stimulus and a load distribution.
As can be seen from the above, the field of application of the mat of the present invention is wide, and various configurations are conceivable in accordance with the application.

[0027]

The resin pipe arrangement mat of the present invention realizes a good tactile sensation that gives a moderate stimulus that is not inferior to that of conventional rush products, resin mats having a large number of grooves or projections or artificial turf. In addition, since it can be used in water places, its use range is wide,
It can be handled only by the resin pipe arrangement mat. Also, unlike artificial turf, the diameter, height, and color of the partial pipe can be changed, and the pipe obtained by stretching is a sufficient strength member with strength and elasticity, so it is extremely designed It has the advantage of being an excellent and sturdy product.

The resin pipe array mat is easy to manufacture and the necessary equipment is simple, so that the productivity is high. Also, the material cost is extremely low, and the pipe obtained by drawing requires less raw material, so that the product cost can be reduced as a whole. Furthermore, as seen in the above-mentioned example of the flip-flops, the flexible base cloth is cut into a predetermined shape, and has a simplicity that can be easily applied to various uses. As described above, the resin pipe array mat of the present invention realizes the provision of a new mat material having high commercial value and excellent in cost effectiveness as an industrial product.

[Brief description of the drawings]

FIG. 1 is a perspective view showing a mat (first example) made of one resin net.

FIG. 2 is a partial side view of the mat of the first example.

FIG. 3 is a partially enlarged side view showing a state of a pipe particularly at a heel portion when the mat of the first example is stepped on with a foot.

FIG. 4 is a perspective view showing a production line of the mat of the first example.

FIG. 5 is a view taken in the direction of arrows AA in FIG. 4, showing a stage in which the heating plate is lowered between the sent resin net and the pipe.

FIG. 6 is a view taken in the direction of arrow AA in FIG. 4, showing a stage in which the end surface of the pipe advanced to the heating plate is brought into contact with the heating plate.

FIG. 7 is a view on arrow AA in FIG. 4 showing a stage in which the heating plate is retracted upward.

FIG. 8 is a view taken in the direction of arrows AA in FIG. 4, showing a stage in which the end surface of the pipe that has been melted is pressed against a resin net.

FIG. 9 is a view taken in the direction of arrows AA in FIG. 4, showing a stage in which the pipe is cut by lowering the cutter between the support frames.

FIG. 10 is a view on arrow AA in FIG. 4 showing a stage in which the pipe is retracted together with the support frame.

FIG. 11 is a partial side view corresponding to FIG. 2 of a mat (second example) in which a pipe has a sandwich structure with two resin nets.

FIG. 12 is a view showing a stage showing welding of a second resin net and a pipe in the production line of the mat of the second example.
It is a middle AA arrow line view.

FIG. 13 is a view showing a stage in which welding of the second resin net and the pipe is performed in the mat production line of the second example.
It is a middle AA arrow line view.

FIG. 14 is a diagram of a mat in which two layers of pipes are arranged at the same position.
It is a fairly partial aspect.

FIG. 15 is a side view corresponding to FIG. 2 of a mat in which pipes are arranged in two layers at different positions.

FIG. 16 is a partial side view corresponding to FIG. 2 of a mat in which pipes are arranged in two layers at different positions.

FIG. 17 is a side view corresponding to FIG. 2 of a mat corresponding to the first example in which pipes are arranged on an apertured resin sheet.

FIG. 18 is a partial side view corresponding to FIG. 2 of a two-layer mat in which pipes having different diameters are arranged on an apertured resin sheet and a resin net, respectively.

FIG. 19 is a perspective view illustrating the entire mat of the second example.

FIG. 20 is a partially cutaway perspective view of a flip flop (third example) to which the mat of the second example is applied.

FIG. 21 is a bed mat to which a three-layer mat is applied (No. 4)
It is a partially broken perspective view of Example).

FIG. 22 is a partially broken perspective view of a bedding mat (fifth example) to which a one-layer mat using a flexible pipe is applied.

FIG. 23 is a partially cutaway perspective view of a cushion (sixth example) to which a mat having a two-layer structure in combination with an apertured resin sheet is applied.

[Explanation of symbols]

 1 resin net 3 pipe

Claims (3)

[Claims] 1. A resin pipe array mat in which a number of heat-fusible resin pipes arranged at substantially equal intervals are heat-welded to an end face of a heat-fusible flexible base cloth. 2. The flexible base cloth is a resin net.
The described resin pipe array mat. 3. The resin pipe array mat according to claim 1, wherein both end faces of the heat-fusible resin pipe are heat-welded to two flexible base cloths.