JPS63249759A - Mat made of thermoplastic resin and production thereof - 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] 3. Amount of H Now H (Industrial Application Field) The present invention provides cushioning materials, filter mats, plant/seafood rearing mats, and reinforcing materials for civil engineering work.

The present invention relates to a thermoplastic resin mat used as a slope greening protection mat, etc., and a method for manufacturing the same.

(Prior art) A three-dimensional mesh mat in which a large number of continuous monofilaments are entangled with each other and the entangled monofilaments are bonded has irregular voids and is lightweight, so it is used for various purposes. There is.

As disclosed in Japanese Patent Publication No. 58-9186, such a mat has 3 protrusions on its surface, one roller that rotates while being vibrated in the axial direction, and a large number of rollers arranged in the axial direction. It is produced by depositing a number of monofilaments of thermoplastic resin melt onto the roller using an extruder with a disposed spinneret. Thermoplastic resin mats manufactured by this method are
Since the roller is vibrated, the monofilaments spun from the spinnerets arranged in parallel in the vibration direction are sufficiently intertwined with each other, which has the advantage that the strength in that direction is increased. However, there is a limit to improving the strength of the entire mat, and it is difficult to produce a mat with high strength and low porosity.

Japanese Patent Laid-Open No. 57-171749 discloses that a monofilament is spun onto the surface of each of a pair of opposing rotating drums from a large number of spinnerets arranged in the axial direction of each roll, and Form each web and at the point where the two webs are closest.

A method is disclosed in which both webs are overlapped by each rotating drum. A mat produced by such a method has the disadvantage that the monofilaments in each web do not sufficiently extend in the axial direction of the rotating drum, and the strength in this direction is significantly lower than the strength in the direction of one rotation of the drum. Furthermore, since the entanglement in the drum axis direction is insufficient, the produced mat has a low porosity and a high density. High-density mats with low porosity can be used for filters, etc.
For use as cushions, slope protection mats, etc.

The weight per unit area is large, impairing economic efficiency, and when used as a slope protection mat, there is also the disadvantage that the voids are not sufficiently filled with soil, so it cannot be used for such purposes.

Whichever method you use, the resulting mat is.

If the monofilaments are sufficiently intertwined.

Although the tensile and compressive strengths improve to some extent,
It is not possible to manufacture thermoplastic resin mats that require higher strength. If monofilaments are intertwined with each other at a high density in order to improve strength, there is also the drawback that the porosity decreases.

(Problems to be Solved by the Invention) The present invention solves the above-mentioned conventional problems, and its purpose is to produce a thermoplastic resin that has a high porosity, is lightweight, and has excellent tensile strength and compressive strength. The object of the present invention is to provide a mat made of aluminum and a method for manufacturing the same.

(Means for Solving the Problems) The thermoplastic resin mat of the present invention comprises a main body in which a large number of continuous monofilaments made of thermoplastic resin are intertwined with each other and the intertwined portions are bonded, and the main body The thermoplastic resin monofilaments are intertwined and bonded at a high density, and the reinforcing portion is continuous in a predetermined direction, thereby achieving the above object.

The method for producing the thermoplastic resin mat of the present invention is as follows.

An extruder has a large number of spinnerets arranged in parallel in a predetermined direction, and a plurality of protrusion groups consisting of a large number of protrusions are arranged at predetermined intervals on its conveyance surface, a conveyor located below each spinneret of the extruder and moving in a direction perpendicular to the spinneret;

This is a method for manufacturing a thermoplastic resin mat by extruding monofilaments of thermoplastic melt from each of the spinnerets, allowing each extruded monofilament to fall under its own weight, and moving the conveying surface through vibration and movement. The method includes a step of depositing a group of protrusions and a monofilament between each group of protrusions, thereby achieving the above object.

(Example) Examples of the present invention will be described below.

As shown in FIG. 1, the thermoplastic resin mat of the present invention comprises a continuous monofilament (10a) made of thermoplastic resin,
10a... are intertwined with each other at a low density and are bonded at the intertwined portion, and the continuous monofilament 10a made of thermoplastic resin is intertwined with a higher density than the main body portion 11, and the intertwined portion is bonded. It has a reinforcing part 12 bonded to the reinforcing part 12.

For example, the main body 11 of the mat 10 vibrates a large number of continuous monofilaments of thermoplastic resin melt from spinnerets arranged in parallel in a predetermined direction in the direction in which the spinnerets are arranged in parallel. The monofilaments 10a are dropped onto a conveying surface moving in orthogonal directions, and the monofilaments 10a are sufficiently intertwined with each other in a direction perpendicular to the direction in which each monofilament 10a continues.

The monofilaments 10a in the reinforcing part 12 are intertwined with and bonded to each monofilament 10a in the main body part 11. The reinforcing portion 12 corresponds to the continuous direction of each monofilament 10a in the main body portion 11.

It is located between each main body part 11 so as to be continuous in parallel. In this case, each monofilament 1 in the reinforcing part 12
0a is each monofilament 10a in the two main body parts 11
The diameter may be the same as that of the monofilament 10a in the two main body portions 11, but the diameter may be larger than that of each monofilament 10a in the two main body portions 11.

The reinforcing portion 12 may be arranged perpendicularly to the continuous direction of the monofilament lOa in the one main body portion 11 as shown in FIG. It may be arranged so as to be continuous in both the continuous direction of the monofilaments 10a and the direction orthogonal to the continuous direction.

A thermoplastic resin mat having such a structure has a reinforcing portion 12.
Since the load is supported by the two body parts 11, the strength as a whole increases even if the strength of the two main body parts 11 is low. Result 5 body part 1
1 can be made lighter and the porosity of the main body part 11 can be significantly increased.
The mat is made of high-strength thermoplastic resin.

The weight ratio of the main body part 11 and the reinforcing part 12 is 10:1 to 1:1.
is preferred. If the weight of the main body portion 11 is greater than this weight ratio, a sufficient reinforcing effect cannot be obtained.

On the contrary, the weight of the reinforcing portion 12 increases.

The thermoplastic resin mat of the present invention is shown in FIG.

For example, it is manufactured using the apparatus shown in FIG. The apparatus includes a number of spinnerets 3131. ... are arranged in parallel, and a carrier 20 is arranged below the extruder 30.

Extruder 30 extrudes continuous monofilaments of thermoplastic resin melt from each spinneret 31 .

The spinneret 31.31 of the extruder 30. ... is 1 example.

They are arranged in two rows in a predetermined direction.

The conveyor 20 has 9, for example, a belt conveyor 21 and a pedestal 22 that supports the belt conveyor 21. The belt conveyor 21 has a large number of protrusions 23 on its conveying surface 21a.
It has a plurality of protrusion groups 23 consisting of a, 23a, . Each protrusion 23a has a flat top. The conveying direction of the belt conveyor 21 is substantially perpendicular to the direction in which the spinnerets 11 are arranged side by side (the direction indicated by arrow A). Frame 2
2 supports the belt conveyor 21 so as to be able to vibrate in a direction perpendicular to the conveyance direction thereof, that is, in a direction in which the spinnerets 11 are arranged side by side.

The plurality of protrusions 23 arranged on the conveying surface 21a of the belt conveyor 21 are one group, for example, as shown in FIG.

In a direction perpendicular to the conveying direction of the belt conveyor 21.

They are arranged at predetermined intervals. A large number of protrusions 23a of each protrusion group 23 have predetermined gaps.

For example, they are arranged in a houndstooth pattern. Each protrusion group 23 is continuous in the conveyance direction of the belt conveyor 21.

Therefore, the intervals between adjacent protrusion groups 23 are continuously formed in the conveyance direction of the belt conveyor 21.

The distance between adjacent protrusions 2 in each protrusion group 23 is
It is sufficiently larger than the gap between 3a.

The interval between each protrusion group 23 is 2, for example, each protrusion 23a.

When arranged over the entire surface in rows in the moving direction of the conveyance surface 21a, -row or multiple rows of protrusions 23a
It is said that it is the extent to which the .

In the apparatus having such a configuration, the conveyance surface 21a of the belt conveyor 21 is moved around in a predetermined direction indicated by arrow A, and is also vibrated by the pedestal 22 in a direction perpendicular to the direction of the rotation. In this state, the extruder 30
A thermoplastic resin melt is extruded from each spinneret 31 . The thermoplastic resin melt extruded from each spinneret 11 consists of continuous monofilaments 10a, 10a, .
・, and falls.

Each monofilament 10a that fell while being heated was moved once and vibrated onto the conveying surface 2 of the belt conveyor 21.
Reach 1a. On the conveyance surface 21a of the belt conveyor 21, a plurality of protrusion groups 23. ... are arranged, and each monofilament 41 is connected to the flattened top of each protrusion 23a in each protrusion group 23, and the flattened top of each protrusion 23a
The protrusion group 23 further falls between the protrusion groups 23. At this time,
Since the belt conveyor 21 is vibrated in the direction in which the three spinnerets in the extruder 30 are arranged in parallel, the monofilaments Oa that have fallen onto the belt conveyor 21 are in a state where adjacent ones are well intertwined with each other. accumulate.

Between each protrusion group 23 on the belt conveyor 21.

Since the conveyance surface 21a is flat, the monofilament 10
a, 10a, . . . are likely to fall and accumulate, and in this part, the density of the fallen monofilaments 10a is .

The top of each protrusion 23a of the protrusion group 23 and each protrusion 23
The monofilaments 10a are intertwined with each other in a higher density than the monofilaments 10a that fall and accumulate between the three layers. As a result, belt conveyor 2
On the conveying surface 21a of the thermoplastic resin mat 10, a reinforcing portion 12 in which monofilament HOa is intertwined with high density is continuously formed in the conveying direction of the belt conveyor 21.
is manufactured. The 77th and 10th.

For example, it is wound up using a winding machine 50.

The number, number, and arrangement of the spinnerets 31 in the extruder 30 are appropriately set depending on the use of the mat to be manufactured, and may be arranged, for example, in a plurality of rows or in a houndstooth pattern. It may also be a - column. Furthermore, the diameter of the spinneret through which the monofilaments constituting the reinforcing portion 12 are spun is made larger than other spinnerets.

A structure may be adopted in which a large diameter monofilament is used for the reinforcing portion.

It is preferable that the intervals between the respective spinnerets 31 are equal intervals,
The distance between the centers is preferably 2 to 301 m.

If this interval is less than 2 mm, there is a risk that the spun monofilament will adhere to the conveyor surface 21a due to air vibrations, etc., and if it exceeds 30 mm, the belt conveyor 21 may not vibrate. .

Adjacent monofilaments are not sufficiently intertwined with each other, resulting in a decrease in strength.

The diameter of each spinneret 31 is 0.2 to 2. OM is preferred.

If it is less than 0.2 +n, there is a risk that uneven flow will occur when the thermoplastic resin melt is spun out from each spinneret 31, and the pressure inside the extruder 30 must be kept high. If it exceeds 2.0, the diameter of the spun monofilament 10a becomes large, and the weight of the produced mat increases.

The distance from each spinneret 31 to the conveying surface 21a of the belt conveyor 21 varies depending on the diameter of each spinneret 31.

Approximately 3 to 30 cI11 is preferable, and if it exceeds 30 cm, the spun monofilament will be cooled before reaching the conveying surface of the belt conveyor 21, and the fusing ability of the monofilament will decrease.

Each protrusion 23a of the protrusion group 23 arranged on the surface of the belt conveyor 21 in the conveyor 20 has a height of 3 to 10
01 m, and the density is preferably about 1 x 103 to 2 x 10' pieces/M. The height of the protrusions 23a is equal to the thickness of the mat to be molded.For example, when molding the mat to a thickness of 50 mm, the height of the protrusions 23a
The height of 3a is 50fl. If the height of the protrusion 23a exceeds the upper limit value 1100t.

The monofilament does not fully enter the valleys between the protrusions 23a, resulting in uneven thickness of the manufactured mat. The density of the protrusions 23a in the protrusion group 23 is equal to the lower limit lXl
0' pieces/rr? Below this, the elasticity of the molded mat decreases. If the density of the protrusions 23a in the protrusion group 23 exceeds the upper limit value 2X10' pieces/M, the gap between each protrusion 23a in the protrusion group 23 is small, and each monofilament 10a is sufficiently spaced between each protrusion 23a. The molded mat will have uneven thickness.

The shape of the protrusion 23a needs to have a flat top so that each spun monofilament IOa can be deposited on the top without falling off the top.
For example, as shown in FIGS. 6(a) to 6(d), the shapes are one cylinder, nine truncated cones, a truncated pyramid, and a prism.

Each protrusion group 23 corresponds to the conveying surface 21a of the belt conveyor 21.
When the protrusions 23a are arranged at a predetermined density over the entire area, it is preferable to leave an interval such that the protrusions 23a removed to form each protrusion group 23 account for 5 to 35% of the total. If it is less than 5%, the monofilament 10a will not be deposited at a high density between the protrusion groups 23, and the strength of the reinforcing portion will decrease. On the other hand, if it exceeds 35%, the amount of monofilament deposited between each protrusion group 23 increases, and the porosity of the produced mat decreases.
Overall weight increases.

The belt conveyor 21 of the transport body 20 is vibrated in the direction in which the spinnerets 11 are arranged side by side, and due to this vibration, the monofilaments 10a spun from the adjacent spinnerets 11 are sufficiently entangled with each other in the direction of vibration. It is fused. The amplitude of this vibration is 20 to 30.

A frequency range of 100 to 400 times/min is suitable.

The amplitude and frequency are the lower limit of the above range 20t1. If the rotation rate is less than 100 times/min, the monofilaments falling from adjacent spinnerets will not be sufficiently intertwined with each other in the vibration direction, resulting in a decrease in the strength of the formed mat in this vibration direction. Further, even if the upper limit values of 301 m and 400 times/min of the above range are exceeded, the strength of the molded mat in the vibration direction does not improve at all, and the upper limit range is sufficient.

The thermoplastic resin used in the method of the present invention includes:

Polyolefins such as polyethylene and polypropylene,
polyurethane, polyamide, polyester.

Examples include polyvinyl chloride, polycarbonate, etc.
In either case, even those having relatively high melt viscosity can be used.

In the above embodiment, a belt conveyor 21 is used as the conveyor 20, but the belt conveyor 21 is not limited to this, and a rotary roll, for example, may be used, and a group of protrusions 2 may be provided on the conveyance surface of the belt conveyor 21.
3 may be arranged.

Note that when forming the reinforcing portions 12 in the mat 10 so as to be continuous in a direction perpendicular to the continuous direction of the monofilament 10a, protrusions are formed on the conveying surface 21a of the belt conveyor 21 at predetermined intervals in the conveying direction. What is necessary is to arrange the object group 23.

A thermoplastic resin mat 10 was manufactured using the apparatus shown in FIG. Each spinneret 3I in the extruder 30 is arranged in two rows, and the diameter of each spinneret 3I is 0.6 mm.
The distance between centers of 1 is 6111, and the row spacing (distance between centers) is 61
It's Otori. On the other hand, the belt conveyor 2 in the conveyor 20
A protrusion group 23 consisting of a cylindrical protrusion 23a with a diameter of 611 degrees and a height of 10 baking soda is disposed on the conveyance surface 21a of No. 1. Each protrusion group 23 is continuous in the conveyance direction. Each protrusion 23a forms a row along the conveyance direction, and one protrusion group 23 includes a row of eight protrusions 23a. The protrusions 23a in adjacent rows are arranged in a houndstooth pattern as shown in FIG. 5, and the interval between the two rows (distance between the centers of each row) is 6 Nm. What is the interval between adjacent protrusion groups 23?

Within this interval, two rows of protrusions each having a diameter of 6 dragons can be arranged at 1811, with each row having an interval of 6 cranes. Each protrusion 2
The distance between the upper surface of 3a and the spinneret 31 in the extruder 30 is 70 mm.

With such a device, nylon 6 can be used as a thermoplastic resin.
The belt conveyor 21 can be conveyed without vibrating in the direction perpendicular to the conveying direction by using
A mat was manufactured. The thickness and weight (converted to a thickness of 10 m) of the obtained mat were measured. The first measurement result is
Shown in the table.

The obtained mat was cut into 150 mm in the conveyance direction and 50 mm in the spinneret parallel direction, and tested using a tensile tester.
It was pulled in the longitudinal direction (conveyance direction) at a speed of 100 mm/min, and the force (tensile strength) until breakage was measured. This tensile strength was 15.10.

The measurement results are also listed in Table 1.

In addition, the obtained mat was cut into a length of 5ON in the transport direction and 150m in the direction in which the spinnerets are arranged side by side, and was pulled in the longitudinal direction (in the direction in which the spinnerets are arranged side by side) at the same speed using a tensile tester. The strength was measured. This tensile strength is 10.02
Met. The measurement results are also listed in Table 1.

A mat was manufactured using the same apparatus as in Experimental Example 1, except that the height of the protrusions was 80 m1. The thickness and tensile strength of the obtained mat were measured in the same manner as in Experimental Example 1. The measurement results are also listed in Table 1. In the following experimental examples, the thickness, weight, and tensile strength of the obtained 77) were measured in the same manner as in experimental example 1, and the measurement results are also listed in Table 1.

It is the same as Experimental Example 1 except that 20 rows of protrusions extending in the conveyance direction in the actual completion main protrusion group were arranged in parallel in a direction perpendicular to the conveyance direction.

Experimental example 1 except that the rows of protrusions extending in the conveyance direction in the finished work protrusion group were arranged in four rows in a direction perpendicular to the conveyance direction.
It is similar to

Ten rows of each of the protrusions in the leaving group protrusions were arranged in the transport direction so that the distance between the centers was 611, and 10 rows were arranged in the width direction so that the distance between the centers of one row was 611. . As a result, the protrusion groups are arranged at predetermined intervals in the conveyance direction and in a direction orthogonal to the conveyance direction. The protrusions in each adjacent row are not arranged in a houndstooth pattern (they are arranged in an orderly manner on a line perpendicular to the conveyance direction. The distance between the protrusion groups arranged in parallel in the direction of The center-to-center distance was set to 1211.Others were the same as in Experimental Example 1.

Castor Charcoal i In Experimental Example 5, a group of protrusions was arranged such that 20 rows of 20 protrusions were arranged in the transport direction and 20 rows were arranged in a direction perpendicular to the transport direction. The intervals between groups of protrusions arranged in parallel in the conveyance direction and the intervals between protrusions arranged in parallel in a direction perpendicular to the conveyance direction are the same as the rows of protrusions constituting each protrusion group. The distance between the centers of the protrusions was set at 18 so that two rows could be arranged. The rest was the same as in Experimental Example 5.

Accident 1 Case 1 In Experimental Example 1, the belt conveyor 21 was set at an amplitude of 10 f.
i. It was vibrated at a frequency of 200 times/min in a direction perpendicular to the feeding direction. The rest was the same as in Experimental Example 1.

In Sm Shadow Experimental Example 1, the distance between each protrusion group 23 is
The distance between the protrusions 23 is made equal to the distance between the protrusions 23 and 3a. The rest was the same as in Experimental Example 1.

The process was the same as in Experimental Example 1 except that the height of each protrusion 23a was 120 fl.

Two rows of protrusions 23a extending in the conveyance direction form the real blind five-stage protrusion group 23.
A column of The spacing between each protrusion group 23 and others are the same as in Experimental Example 1.

Point 5 ■ The group of protrusions 23 is divided into 50 rows of protrusions 23 extending in the conveyance direction.
Fifty rows of rows a are arranged in parallel in a direction perpendicular to the transport direction.

The experiment was the same as in Experimental Example 1 except that the interval between each protrusion group 23 was set to 12 m, allowing one row of protrusions to be arranged.

Table 1 ■ [ [ □ " ]− " (Effect of the invention) The thermoplastic resin mat of the present invention is thus prepared.

Since the reinforcing parts made of high-density monofilament are arranged so as to be continuous in a predetermined direction between one main body part, when a load is applied to the mat, the load is supported by the reinforcing parts. The main body can be made lighter and the porosity of the main body can be increased. The reinforcing portion has excellent strength because the monofilaments are intertwined with each other at a high density, and can support the entire load applied to the mat.

The method of the present invention allows such mats to be easily produced.

↓-2.Escape from field shear quality- Fig. 1 is a plan view showing a part of the thermoplastic resin mat of the present invention, Fig. 2 and Fig. 3 are respectively heat rays in different experimental examples of the present invention. A plan view showing a part of the plastic resin mat,
FIG. 4 is a schematic side view of the apparatus used to carry out the method of the present invention, FIG. 5 is a plan view of the conveying surface of the belt conveyor,
FIGS. 6(a) to 6(d) are perspective views each showing an example of a protrusion.

DESCRIPTION OF SYMBOLS 10... Thermoplastic resin mat, 10a... Monofilament, 11... Main body part, 12... Reinforcement part, 2
0...Transporter.

21... Belt conveyor, 21a... Conveyance surface, 23
... Projection group, 23a ... Projection, 30 ... Extruder, 31 ... Spinneret.

Figure 5 Figure 6

Claims (5)

[Claims] 1. A main body part in which a large number of continuous monofilaments made of thermoplastic resin are intertwined with each other and the intertwined parts are glued together; A thermoplastic resin mat comprising a continuous reinforcing portion and. 2. The thermoplastic resin mat according to claim 1, wherein the reinforcing portion is continuous in parallel to the continuous direction of each monofilament of the main body portion. 3. The thermoplastic resin mat according to claim 1, wherein the reinforcing portion is continuous in a direction perpendicular to a direction in which the monofilaments of the main body are continuous. 4. 3. The thermoplastic resin mat according to claim 2, wherein the monofilament of the reinforcing part has a larger diameter than the monofilament of the main body part. 5. An extruder has a large number of spinnerets arranged in parallel in a predetermined direction, and a plurality of protrusion groups consisting of a large number of protrusions are arranged at predetermined intervals on its conveyance surface, This is a method for producing a thermoplastic resin mat by a conveyor positioned below each spinneret of an extruder and moving in a direction perpendicular to the spinneret, and a thermoplastic molten material is produced from each spinneret. A step of extruding the monofilament, a step of causing each extruded monofilament to fall under its own weight, and a step of depositing each monofilament between a group of protrusions on the conveying surface that vibrates and moves and each group of protrusions. A method for producing a thermoplastic resin mat.