JPS59100752A - Production of mat - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a mat used as an entrance mat, a floor mat, etc., and more particularly to a method of manufacturing a mat as shown in FIGS. 1 and 2.

FIGS. 1 and 2 are partially enlarged views showing an example of a mat/nod according to the present invention, in which 1 is a mat main body and 2 is a reinforcing layer. The main body 1 includes a plurality of spiral bodies 10 in which a large number of loops are continuous in an upright state.
The spiral bodies 10 are formed adjacent to each other on the left and right, and meander in a zigzag shape.

In this snow, 4911 bodies 10 are, for example, 0.5 to 0 in diameter.
．． It is formed by a filament made of synthetic resin with a diameter as small as 6.

Further, the reinforcing layer 2 may be a filamentous material similar to the above, or a plurality of rows of planar S/Nlliral material 2 that are continuous in a zigzag shape in a laid down state.
The reinforcing layer 2 is integrally fixed to the lower surface of the main body 1. In the mat configured in this way, the mat main body 1 has high elasticity in the thickness direction and exhibits a high cushioning effect, and the mat main body 1 is reinforced by the reinforcing layer 2, suppressing the elongation of the man-nod main body 1. It has characteristics such as being able to

The purpose of this invention is to develop a pine i.
The purpose of this invention is to provide a method for manufacturing the same.

The present invention is a method for manufacturing a mat comprising a mat main body and a reinforcing layer integrally provided on the lower surface of the mat main body, the method comprising a plurality of nozzles provided at predetermined intervals in the left and right direction in the discharge section of an extruder. "Double extrusion" is achieved by simultaneously extruding a thermoplastic resin material in a molten state in the form of a filament from a horizontal moving surface toward a vertical barrier placed on a horizontal moving surface, and moving the moving surface in a direction away from the nozzle. By forming multiple rows of spiral bodies in which a large number of loops are continuous in an upright state on the moving surface by the thread-like body, and by reciprocating the moving surface in the left and right direction relative to the nozzle with a predetermined stroke. The mat main body is formed by continuously forming each row of spiral bodies in a zigzag shape.

Embodiments of the present invention will be described below with reference to the drawings. 6th
Figures 4 and 4 show the apparatus used to carry out the present invention, in which the filter is an extruder, the filter 0 is the hopper of the extruder filter, and 31 is the discharge section of the extruder 6. It is T-tie. This T die slot 1 has several nozzles 32-
・We have established Note that although the illustrated example shows a pipe-shaped nozzle, the nozzle may be formed by a plurality of holes provided in the P-tie 31. 66 is a bed, and 4 is a belt conveyor installed on this bed. This conveyor 4 includes a driving roller 41, a driven roller 42, and a belt 46.
The rotation of both rollers 41 and 42 causes the belt 4 to move counterclockwise in FIG. 6, that is, the upper surface (movement direction) 44 of the belt 46 moves away from the nozzle 32. Further, the entire conveyor 4 is operated by a suitable means such as a reciprocating slide mechanism using a piston and a crank or a reciprocating mechanism using a hydraulic cylinder. It is configured to be reciprocated 30 to 60 times). Further, near the rear end of the conveyor 4, a vertical barrier 4o is removably installed over the entire width of the conveyor 4.

In addition, various thermoplastic resins can be used as materials for the mat main body 1 and reinforcing layer 2 that constitute the mat.
Although the type is not particularly limited, vinyl chloride resin is usually used because it is advantageous in terms of cost, processability, etc. In this case, it has been experimentally confirmed that it is appropriate to use vinyl chloride resin pellets with the ingredients shown below as the raw material for the mat body 1.

Vinyl chloride resin (degree of polymerization 1050) 100i"
Plastic agent 6゜Colloidal calcium 15 Stabilizer, pigment 2 To manufacture this mat main body 1, the above-mentioned vinyl chloride resin pellets are loaded into an extruder filter via a hopper 60, and then screwed (not shown) as is well known. Then move it to the discharge side and heat it to melt it.

Then, this molten material is passed through each nozzle 6 of the T-die 61.
2... are simultaneously extruded in the form of threads toward the barrier 40. The filament 11 pushed out from each nozzle 62 collides with the barrier 40 as shown in the fifth image). In this state, start the belt conveyor 4 and move the moving surface 4.
4 is gradually moved forward, each filament 11... is repeatedly buckled and tensile, resulting in ja 5 (+3
), a three-dimensional spiral shape, that is, a circular or elliptical loop is formed in an upright and continuous spiral shape on the moving surface 44. At the same time, the belt conveyor 4 is reciprocated in the left and right direction with a predetermined stroke, so that each of the spiral bodies 1o... is continuously formed while meandering in a zigzag shape as shown in FIG. 5 (C1). , a mat main body 1 having a predetermined width and thickness as an assembly of a large number of loops made of filamentous bodies 11 is continuously manufactured on the moving surface 44.After the mat main body 1 is manufactured, both left and right end portions are separated. Trim accordingly.

This mat main body 1 has each spiral body 10 as described above.
... are formed simultaneously in multiple rows, resulting in excellent productivity, and since each spiral body 10... meanders in a zigzag pattern, the effective width of each spiral body 10 increases, resulting in a large number of ) Ii-pu are distributed in a uniform number and arranged without any gaps. Moreover, the adjacent spiral bodies 10
．． The 10 loops are intertwined with each other, resulting in a masoto body 1 with excellent elasticity and shape retention. Further, the meandering interval of the spiral bodies 10 forming the mat main body 1 can be arbitrarily changed by changing the feeding speed of the moving surface 44, etc. For example, each spiral body 10...
It is also possible to have a structure in which one loop is made to meander from side to side.

Note that even if the material in the molten state inside the extruder filter is extruded as it is, it will be cooled to some extent by the outside air, or the material will be insufficiently cooled and will be soft, making it difficult to form an accurate spiral shape. Therefore, in practice, it is necessary to actively cool the extruded material to promote assimilation. As specific means for this, for example, the material may be cooled immediately before extrusion by constantly dripping water droplets at the tip of the nozzle 32, or by blowing air near the tip of the nozzle 62 with an air blower to cool the material. You may. When the material is cooled in this way, the filamentous bodies 11 that reach the moving surface 44 become semi-solidified and draw an orderly spiral pattern. Further, the barrier 40 shown in - is removed at an appropriate position when it moves forward together with the moving surface 44.

On the other hand, when forming the reinforcing layer 2, as shown in FIG. The body 21 falls onto the moving surface 41, and due to repeated buckling and pulling action, it forms a flat spiral shape.
That is, a large number of circular or elliptical loops are formed in a continuous spiral shape in an inverted state on the moving surface 44, and the reinforcing layer 2 is formed by this spiral body 20.

Note that, like the spiral body 10 described above, this spiral body 20 is made by reciprocating the belt conveyor 4 in the left-right direction with a predetermined stroke, so that the planar spiral body 20 is
A reinforcing layer 2 having a meandering mesh shape is obtained.

By fixing the mat main body 1 mentioned above to the upper surface of this reinforcing layer 2 by adhesive or other means, a pine tree as shown in FIG. 2 is formed.
・Or is formed. Note that the reinforcing layer 2 is formed in advance, and the reinforcing layer 2 in a semi-solidified state is placed on the belt conveyor 4''.
This second mat body 1 is formed as described above, and the misalignment occurs because the thread-like bodies 21 of the reinforcing layer 2 and the thread-like bodies 11 of the mat body 1 are bonded together by their adhesive force, and the reinforcing layer 2 and the mat body 1 are polymerized. It will be naturally integrated in the state.

It should be noted that the mat produced as described above may be used as a product as it is, or it may be subjected to shape-retention processing and IE'.
It is desirable that all tf% type processing be completed. The shape retention V is carried out by spraying adhesive onto the mat wood body 1,
This processing strengthens the adhesive force between the mat main body 1 and the reinforcing layer 2, and the spiral body 10 that forms both.
20 shape retention power is strengthened. In addition, the IJl compression shaping process is usually performed by heating the pine wood and pressing it thickly in seven directions with a roll or the like after the above-mentioned shape-retaining process, and this process smoothes the surface of the mat body 1. and the thickness is made uniform.

Further, the reinforcing layer 2 does not necessarily need to be formed by the planar spiral body 20, and may be formed by a sheet-like member as described below. That is, as shown in FIG. 7, a resin material 61 made by adding a foaming agent to a vinyl chloride paste resin sol (polymerization degree of 1400) is placed in a shallow tank-shaped mold 60, and a matte material is placed in this material 61. Main body 1
The entire material 61 is heated with the lower layer immersed in it to foam and gel the material 61, and then cooled and solidified. This deviation occurs when the sheet-like reinforcing layer 6 is formed, and at the same time, the lower layer part of the mat main body 1 is embedded in the upper part of the reinforcing layer B, so that the mat is formed. It goes without saying that a sheet-like reinforcing layer formed separately in advance may be fixed downwardly to the mat main body 1 with an adhesive.

Furthermore, the present invention can be implemented in many different ways than those described above, and some examples will be shown below.

[B] Method of moving the moving surface 44 In the above embodiment, the moving surface 44 is moved by the belt conveyor 4, but as shown in FIG. 8, a horizontal table 5 is provided on the bed 66, The upper surface (moving surface) 51 of the table 5 may be configured to be moved in the front-rear direction and left-right direction by means such as a gear-type moving mechanism using a rack and pinion. In this case, the barrier 50 can be fixed to the front end of the moving surface 51, and the mold 60 containing the sheet material 61 shown in FIG. 7 can be placed on the moving surface 51, or the moving surface 51 can be The material 61 is formed into a mold shape and a material 61 is stored therein, and a spiral body 10 is formed from the material 61 to form the mat main body 1. At the same time, the mat main body 1 and the reinforcing layer 2 are integrated. You may also make it

[Opening] Relative movement of the moving surface 44 in the left-right direction with respect to the nozzle 32 In the case where the moving surface 44 is formed by the conveyor belt 43, the rear end roller 42 of the conveyor 4 is configured to move in the left-right direction, and By forming the conveyor belt 43 from a flexible material, only the rear portion of the moving surface 44 may be reciprocated in the left-right direction with a predetermined stroke. Furthermore, when a small and lightweight extruder 6 is used, it may be moved in the left and right direction.

[C] Structure of the barrier 40 In the above embodiment, the barrier 40 is either erected on the moving surface 44'' or is held movably up and down by an appropriate holding assembly, so that when moving the moving surface 44, It may be configured to raise the temperature. In addition, instead of the barrier 40, for example, a type of air curtain may be formed by blowing air from the n'J direction of the conveyor 4 toward the nozzle 62, and this may be used as a barrier for forming the three-dimensional pile body 10. It is also an iS ability to act.

Further, this air blowing can also be effectively used to cool the material.

As explained above, in the present invention, a mat main body having a predetermined width is obtained by simultaneously and continuously forming a plurality of rows of three-dimensional spiral bodies made of thread-like bodies made of thermoplastic resin. Therefore, according to the present invention, a mat with high elasticity in the thickness direction can be efficiently manufactured using simple equipment, the mat can be mass-produced, and costs can be kept low. Furthermore, by making each of the spiral bodies meander in a zigzag pattern, the loops of each spiral body are evenly distributed and arranged without any gaps, and the loops of adjacent spiral bodies are intertwined with each other, resulting in excellent functionality and shape retention. This makes it possible to obtain a mat main body that has properties.

[Brief explanation of the drawing]

FIGS. 1 and 2 are partially enlarged exploded perspective views of a mat manufactured according to the present invention, and side views of the same assembly, and FIGS. The same plan view, FIG.
The figure is a sectional view showing another example of the reinforcing layer forming method.
The figure is a schematic side view showing another example of an apparatus for carrying out the present invention. DESCRIPTION OF SYMBOLS 1... Mat main body, 2, 6... Reinforcement layer, 6... Extruder, 10... Spiral body, 11... Filiform body, 6
2... Nozzle, 40.50... Barrier, 44.51.
...Moving surface. 1 patentee Yoshi An Kuriyama Agent Patent attorney Etsuka Kotani - 1 - Dispute;'j
:? glj,'i:F Tj! 2: (Voluntary) First day of January 1981, 171, good official, Kazuo Wakasugi, 1, Indication of matter 1'1, 1982, 1, Revised application No. 2079/I 0, 2, Invention Name of 7tsu l- no Tsuj132! Method 33, Correction @ Ruruichi iV? =]i (Relationship with i 1?j revised applicant's name)
111 Zen Kei 1, agent 0 1-chome, Nishihonmachi, Nishi-ku, Osaka [110-3 Shin Matsuoka Building 6, subject of amendment] [Special feature 1] Claims 1 and [Invention] [detailed description] and [brief description of drawings] columns. 7. Contents of amendment (1) The column "Claims of Patent FiQ" in Specification i is amended as shown in the attached sheet. (2) In the 8th line of the 2nd line of the specification, there is a line that says ``a number of loops are continuous in an erected state.'' This is a continuum of loops that can be erected. 1 and corrected. (3) Detailed accounting, page 3, 13 <'+1'' to 19
This is the line Ll-1 extruded and formed. '' should be corrected as follows. [The threads extruded from each nozzle are erected in a continuous C-loop shape on the dirt moving surface, and the moving surface is reciprocated in the left and right direction relative to the nozzles with a predetermined stroke. 1! In particular, each row of the above-mentioned loops is formed in a jig shape to form the above-mentioned pine 1 to the main body. (4) On page 6, line 7 to line 13 of the specification, the phrase ``s''y, continuous while facing forward'' is corrected as follows. A loop is formed in a continuous three-dimensional spiral shape in an upright position on the moving surface/14 soil.At the same time, the belt conveyor 4 is moved in a predetermined direction from L (-i to j). If the loop is reciprocated, each spiral body 1° as a continuum of the above loops is shown in Fig. 5 (C).
"Meandering in a zigzag pattern as shown in" (5) From page 7, line 13 of page 8 to line 5, line 1 of page 8, the text "~ nozzle 32 ~ also" has been deleted as follows. Correct. ``In addition, the molten material in the extruder 3 is cooled to some extent by the outside air on the platform where it is extruded as is.
Unfortunately, there is a situation where the cooling is insufficient and the material remains soft. Actually, it is necessary to actively cool the extruded H stone to prevent it from solidifying. (For example, water droplets are constantly dripped at the tip of the nozzle 32 to cool fJJ before extruding the material.
l, or air blowing (depending on the nozzle 32
1. You may cool the area by blowing air near the tip. When the material is cooled I+'1J in this way, the filament 1'1 reaching the moving surface 44 becomes semi-solidified and stands up continuously in a loop shape as described above. However, even with this cold filling, the filament 11 is still in an unstable state of semi-solidification as described above, so the loop shape due to the filament 1/< 11 and the direction of the connections between the loops, etc. If it is not necessarily uniform, it is not limited to C, and it will show an irregular aspect. For now, the term "spiral body" or "spiral shape" as a continuum of loops refers only to a spiral shape in the strict sense that the loops are of a constant shape and continue regularly in a constant direction. Rather, it includes various modifications thereof, and in order to make it easier to understand the content of the present invention, the figure shows an orderly spiral shape as an example of a loop continuum. This point is explained below in the reinforcing layer 2.
The same applies to a three-way spiral body or spiral shape. By the way,” (6) Mei If M page 8 m 13bFl to 1155
The line ``formed in a planar form'' is corrected as ``the loop is continuous in a lying state on the moving surface 4/l'' and ``is formed in a planar spiral shape''. (7) In the 16th line of page 12 of the detailed reading, ``one solid spiral'' is interpreted as [a continuum of erecting loops] by nJ. (8) On page 13 of the specification, the words "I-spiral body" written in the second line of J3-C, the third and fourth lines, and the fifth line are replaced with "I-spiral body". loop continuum” and iiJ
+J2. (0) Akira full ni Page 13, line 20, “1
0...Spiral body" has been corrected as [10...Spiral body 1 as a loop continuum. 2. Claim 1: A method for manufacturing a pine 1 comprising a mat body and a reinforcing layer integrally provided on the lower surface of the pine 1 to the body.
1. A plurality of nozzles are installed at predetermined intervals in the left EjIy direction on the discharge part of the extruder. The thermoplastic resin material in a molten state is moved from the horizontal moving surface to the vertical wall (14) while simultaneously extruding it in the form of a thread, while moving the moving surface in the direction away from the nozzle. By doing so,
Upper 1 The filament 1 extruded from the nozzle is
-1- is d3 and the serial sales request is 2 Otomi KJL crying.
By being able to move back and forth in the j direction at a predetermined speed,
A method for manufacturing a mat, characterized in that each of the above loops 48 and 48 is shaped like a jig.

Claims (1)

[Claims] 1. A method for producing a mat consisting of a mat body and a reinforcing layer integrally provided on the lower surface of the mat body, the method comprising: a mat body comprising a mat body; and a reinforcing layer integrally provided on the lower surface of the mat body; By simultaneously extruding the molten thermal 5J plastic resin material in the form of a thread toward a vertical barrier provided on a horizontal moving surface, and moving the moving surface in a direction away from the nozzle, extrusion is achieved. A number of loops or a plurality of rows of spiral bodies that are continuous in an upright state on the moving surface are formed by the thread-like bodies, and the moving surface is moved in a predetermined direction in the left and right direction relative to the nozzle. A method for manufacturing a mat, characterized in that the mat main body is formed by continuously forming each row of spiral bodies in a zigzag shape by reciprocating the spiral bodies.