JPS6044418B2 - Matuto manufacturing method - Google Patents

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.

1 and 2 are partially enlarged views showing an example of a mat according to the present invention, in which 1 is a mat main body and 2 is a reinforcing layer.

The mat main body 1 is made up of multiple rows of spiral bodies 10 which are a continuous body of loops that stand up, and each spiral body 10 is formed adjacent to each other on the left and right, and each has a zigzag pattern. It is meandering in a shape. The spiral body 10 is formed of a filament made of synthetic resin and has a small diameter of, for example, about 0.5 to 0.6 wglt.
Further, the reinforcing layer 2 is composed of a plurality of rows of planar spiral bodies 20 in which thread-like bodies similar to those described above are continuous in a zigzag shape, and this reinforcing layer 2 is integrally fixed to the lower surface of the mat main body 1. In the mat configured in this way, the mat body 1 has high elasticity in the thickness direction and exhibits a high cushioning effect, and the mat body 1 is reinforced by the reinforcing layer 2.
It has characteristics such as being able to suppress elongation of the mat main body 1. An object of the present invention is to provide a method for manufacturing a mat that can efficiently manufacture such a mat using simple equipment and at low cost.

The present invention is a method for manufacturing a mat consisting of a mat main body and a reinforcing layer integrally provided on the lower surface of the mat main body. A thermoplastic resin material in a molten state is simultaneously extruded in a thread form toward a vertical barrier provided on a horizontal moving surface, and the moving surface is moved in a direction away from the nozzles, thereby extruding it from each of the nozzles. The continuous body of the loop is made to stand up continuously in a loop shape on the movable surface, and the movable surface is reciprocated in the left and right direction with a predetermined stroke relative to the nozzle. Each row is formed in a zigzag shape to constitute the mat main body. Embodiments of the present invention will be described below with reference to the drawings.

3 and 4 show the apparatus used to carry out the present invention, in which 3 is an extruder, 30 is a hopper of this extruder 3, and 31 is provided at a discharge section of the extruder 3. It is a T-die. This T-die 31 has a plurality of nozzles 32 at predetermined intervals (for example, about 1C1!) on the left and right sides.
... has been established. Note that although a vibrator-shaped nozzle is shown in the illustrated example, the nozzle may be formed by a plurality of holes provided in the T-die 31. 33 is a bed, and 4 is a belt conveyor provided on the bed 33.

This conveyor 4 consists of a driving roller 41, a driven roller, and a belt 43, and the rotation of both rollers 41 and 42 rotates the belt 43 counterclockwise in FIG.
The upper surface (moving surface) 44 of is configured to move in a direction away from the nozzle 32. Furthermore, the entire conveyor 4 moves a predetermined stroke left and right on the bed 33 (for example, 30 strokes per minute with a width of 1 cm) by an appropriate means such as a reciprocating slide mechanism using a piston and a crank or a reciprocating mechanism using a hydraulic cylinder. ~64) is configured to reciprocate. Further, near the rear end of the conveyor 4, a vertical barrier 40 is removably installed over the entire width of the conveyor 4. Various thermoplastic resins can be used as the material for the mat body 1 and the reinforcing layer 2 that constitute the mat, and the types are not particularly limited, but vinyl chloride is usually used because it is advantageous in terms of cost, processability, etc. Uses resin. 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 main body 1. Vinyl chloride resin (polymerization degree 1050) 100 plasticizer
60 colloidal calcium
15 Stabilizers, pigments
2. To manufacture this mat body 1, the vinyl chloride resin pellets described above are loaded into the extruder 3 via the hopper 30, transferred to the discharge side by a screw (not shown) as is well known, and heated to melt. let

Then, this molten material is transferred to each nozzle 3 of the T-die 31.
At the same time, they are extruded in the form of threads from the tips of 2... toward the barrier 40. The filament 11 extruded from each nozzle 32 collides with the barrier 40 as shown in FIG. 5A. If the belt conveyor 4 is started in this state and the moving surface 44 is gradually moved forward, each filament 11... will undergo repeated buckling and tensioning as shown in FIG. 5B. In this way, the loop is formed in a continuous three-dimensional spiral shape in an upright state on the moving surface 44. At the same time, if the belt conveyor 4 is reciprocated in the left and right direction with a predetermined stroke, each spiral body 10 as a continuous body of the loops...
. . is formed in a meandering zigzag shape as shown in FIG.
are produced continuously. After the mat main body 1 is manufactured, both left and right ends are trimmed as necessary. This mat main body 1 has excellent mass productivity because multiple rows of spiral bodies 10 are simultaneously formed as described above, and each spiral body 10 meanders in a zigzag pattern. As a result, the effective width of each spiral body 10 increases, and a large number of loops are uniformly distributed and arranged without gaps. Furthermore, the loops of the adjacent spiral bodies 10, 10 are intertwined with each other, resulting in a mat main 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 each loop meanders left and right. In addition, extruder 3
Even if the molten material inside is extruded as it is, it will be cooled to some extent by the outside air, but there is a situation where the cooling is insufficient and the material is too soft.

Therefore, in practice, it is necessary to actively cool the extruded material to promote solidification. As specific means for this, for example, water droplets may be constantly dripped at the tip of the nozzle 32 to cool the material immediately before extrusion, or a blower may be used to cool the material by blowing air around the tip of the nozzle 32. It's okay. If the material is cooled in this way, the moving surface 44
The filamentous body 11 reaches the semi-solidified state and stands up continuously in a loop shape as described above. However, even after cooling in this way, the filament 11 is still in an unstable state of being semi-solidified as described above.
The loop shape according to No. 1, the direction of connection of the loops, etc. are not necessarily uniform, and exhibit an irregular aspect. Therefore, the term "spiral body" or "spiral shape" as a continuum of loops here does not refer only to a spiral shape in the strict sense that the loops are of a constant shape and continue regularly in a constant direction; This includes various modifications, and the figure shows an orderly spiral shape as an example of a loop continuum in order to make it easier to understand the content of the present invention.
This point also applies to the spiral body or spiral shape of the reinforcing layer 2, which will be described below. By the way, the barrier 40 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. 6, with the barrier 40 removed, the material is extruded in the form of threads from the nozzle 32 in the same manner as described above), and when the conveyor 4 is started, the extruded threads are 21 falls onto the moving surface 41, and through repeated buckling and tensioning, a loop is formed on the moving surface 44 in an inverted state in a continuous planar spiral shape. A reinforcing layer 2 is then formed.

Note that, like the spiral body 10 described above, this spiral body 20 is obtained by reciprocating the belt conveyor 4 in the left-right direction with a predetermined stroke, thereby obtaining a mesh-like reinforcing layer 2 in which the planar spiral body 20 meanders in a zigzag pattern. It will be done. By fixing the mat main body 1 to the upper surface of the reinforcing layer 2 by means of adhesive or the like, a mat as shown in FIG. 2 is formed. Note that if the reinforcing layer 2 is formed in advance, the reinforcing layer 2 in a semi-solidified state is placed on the belt conveyor 4, and the mat main body 1 is formed thereon as described above, the filaments of the reinforcing layer 2 21 and the filamentous body 11 of the mat main body 1 are bonded together by these adhesive forces, and the reinforcing layer 2 and the mat main body 1 are naturally integrated in a polymerized state. Although the mat produced as described above may be used as a product as it is, it is desirable to subject the mat to shape retention processing and pressure shaping processing. The shape-retaining process is performed by spraying adhesive onto the mat body 1, and this process strengthens the adhesive force between the mat body 1 and the reinforcing layer 2, and also strengthens the spiral bodies 10, 20 that form both. The shape-retention ability of the body is strengthened. In addition, the pressure shaping process is usually performed by heating the mat and applying pressure in the thickness direction with a roll or the like after the above-mentioned shape-retaining process, and by this process, the surface of the mat body 1 is smoothed and The thickness is made uniform. Further, the reinforcing layer 2 does not necessarily need to be formed from the planar spiral body 20, and may be formed from a sheet-like member as described below.

That is, as shown in FIG. 7, a sol (polymerization degree of 1400) of vinyl chloride paste resin is placed in a shallow tank-shaped mold 60.
A resin material 61 made by adding a foaming agent to the material 61 is placed, and the lower layer of the mat body 1 is immersed in the material 61, and the whole is heated to foam and gel the material 61, and then cooled and solidified. In this way, the sheet-like reinforcing layer 6 is formed, and at the same time, the lower part of the mat main body 1 is embedded in the upper part of the reinforcing layer 6, thereby forming a mat. It goes without saying that a sheet-like reinforcing layer formed separately in advance may be fixed to the lower surface of 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 above the pet 33. , the upper surface (moving surface) 5 of this table 5
1 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 a mold 60 containing a sheet material 61 shown in FIG.
1 is formed into a mold shape, a material 61 is stored therein, and a spiral body 10 is formed on the upper surface of this material 61 to form the mat main body 1. At the same time, the mat main body 1 and the reinforcing layer 2 are formed. It is also possible to integrate them. [Mouth] Nozzle 3
Relative movement of the movement surface 44 in the left-right direction with respect to the movement surface 4
4 is formed by a belt conveyor 43, the roller 42 on the rear end side of the conveyor 4 is configured to move in the left-right direction, and the conveyor belt 43 is made of a flexible material. Only the rear portion of the surface 44 may be reciprocated in the left-right direction with a predetermined stroke.

Further, when a small and lightweight extruder 3 is used, it may be configured to move in the left-right direction. [C] Structure of the barrier 40 In the above embodiment, the barrier 40 is erected on the moving surface 44, but it is held movably up and down by an appropriate holding member, and when moving the moving surface 4, the barrier 40 is raised and lowered. It may also be configured to allow

Further, instead of the barrier 40, it is also possible to form a saw-type air curtain by blowing air from the front of the conveyor 4 toward the nozzle 32, and to have this act as a barrier for forming the three-dimensional spiral body 10. It is. Further, this air blowing can also be effectively used to cool the material. As explained above, in this invention, a mat main body of a predetermined width is obtained by simultaneously and continuously forming a plurality of rows of upright loops made of filaments made from 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. Moreover, by meandering each of the above loop continuum bodies in a zigzag pattern, the loops of each loop continuum body are uniformly distributed and arranged without gaps, and the loops of adjacent loop continuum bodies are intertwined with each other, resulting in excellent functionality. This makes it possible to obtain a mat main body that has shape retention properties.

[Brief explanation of drawings]

FIGS. 1 and 2 are partially enlarged exploded perspective views and assembled side views of a mat manufactured according to the present invention, and FIGS. 3 and 4 are schematic side views and FIGS. The same plan view, FIGS. 5A to 5C are perspective views for explaining the method for forming the mat main body, FIG. 6 is a perspective view for explaining the method for forming the reinforcing layer, and FIG. 7 is a perspective view for explaining the method for forming the reinforcing layer. FIG. 8 is a schematic side view showing another example of the apparatus for carrying out the invention. 1...Mat body, 2, 6...Reinforcement layer, 3...Extruder, 10...Spiral body as loop continuous body, 11... ... filamentous body, 32.
... Nozzle, 40, 50 ... Barrier, 44
, 51...Moving surface.

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, in which the mat is melted from a plurality of nozzles installed at predetermined intervals in the left and right direction in the discharge section of an extruder. The thermoplastic resin material in the state is extruded from each of the above nozzles by simultaneously extruding the thermoplastic resin material in the form of a thread toward a vertical barrier placed on a horizontal moving surface, while moving the moving surface in a direction away from the nozzle. By making the filament stand up in a continuous loop shape on the movable surface and reciprocating the movable surface in the left and right direction relative to the nozzle with a predetermined stroke, the continuum of loops is formed in each row. A method for manufacturing a mat, characterized in that the mat main body is formed by forming the mat body in a zigzag shape.