WO2004095990A1 - Apparatus for manufacturing non-slip sheet for mat and it’s the using sheet - Google Patents

Apparatus for manufacturing non-slip sheet for mat and it’s the using sheet Download PDF

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Publication number
WO2004095990A1
WO2004095990A1 PCT/KR2003/001194 KR0301194W WO2004095990A1 WO 2004095990 A1 WO2004095990 A1 WO 2004095990A1 KR 0301194 W KR0301194 W KR 0301194W WO 2004095990 A1 WO2004095990 A1 WO 2004095990A1
Authority
WO
WIPO (PCT)
Prior art keywords
sheet
roller
slip
unit
pattern
Prior art date
Application number
PCT/KR2003/001194
Other languages
French (fr)
Inventor
Jong-Hee Chae
Ho-Bong Ki
Original Assignee
Jong-Hee Chae
Ho-Bong Ki
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from KR10-2003-0027611A external-priority patent/KR100517024B1/en
Priority claimed from KR1020030027585A external-priority patent/KR20040010096A/en
Application filed by Jong-Hee Chae, Ho-Bong Ki filed Critical Jong-Hee Chae
Priority to JP2004571351A priority Critical patent/JP2006513802A/en
Priority to AU2003246280A priority patent/AU2003246280A1/en
Publication of WO2004095990A1 publication Critical patent/WO2004095990A1/en

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47G—HOUSEHOLD OR TABLE EQUIPMENT
    • A47G27/00—Floor fabrics; Fastenings therefor
    • A47G27/02—Carpets; Stair runners; Bedside rugs; Foot mats
    • A47G27/0212—Carpets; Stair runners; Bedside rugs; Foot mats to support or cushion
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/22—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of indefinite length
    • B29C43/222—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of indefinite length characterised by the shape of the surface
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/22—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of indefinite length
    • B29C43/24—Calendering
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C59/00—Surface shaping of articles, e.g. embossing; Apparatus therefor
    • B29C59/02—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing
    • B29C59/04—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing using rollers or endless belts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/30—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/06—Embossing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60N—SEATS SPECIALLY ADAPTED FOR VEHICLES; VEHICLE PASSENGER ACCOMMODATION NOT OTHERWISE PROVIDED FOR
    • B60N3/00—Arrangements or adaptations of other passenger fittings, not otherwise provided for
    • B60N3/04—Arrangements or adaptations of other passenger fittings, not otherwise provided for of floor mats or carpets
    • B60N3/048—Arrangements or adaptations of other passenger fittings, not otherwise provided for of floor mats or carpets characterised by their structure
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
    • D06N7/0063—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf
    • D06N7/0071—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/16—Cooling
    • B29C2035/1616—Cooling using liquids
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C59/00—Surface shaping of articles, e.g. embossing; Apparatus therefor
    • B29C59/02—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing
    • B29C59/04—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing using rollers or endless belts
    • B29C59/046—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing using rollers or endless belts for layered or coated substantially flat surfaces
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2009/00—Use of rubber derived from conjugated dienes, as moulding material
    • B29K2009/06—SB polymers, i.e. butadiene-styrene polymers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2023/00—Use of polyalkenes or derivatives thereof as moulding material
    • B29K2023/16—EPM, i.e. ethylene-propylene copolymers; EPDM, i.e. ethylene-propylene-diene copolymers; EPT, i.e. ethylene-propylene terpolymers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2027/00—Use of polyvinylhalogenides or derivatives thereof as moulding material
    • B29K2027/06—PVC, i.e. polyvinylchloride
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/732—Floor coverings
    • B29L2031/7324—Mats
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/744—Non-slip, anti-slip
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2471/00—Floor coverings
    • B32B2471/04—Mats
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/08—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the cooling method
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/15—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer being manufactured and immediately laminated before reaching its stable state, e.g. in which a layer is extruded and laminated while in semi-molten state
    • B32B37/156—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer being manufactured and immediately laminated before reaching its stable state, e.g. in which a layer is extruded and laminated while in semi-molten state at least one layer is calendered and immediately laminated
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2209/00—Properties of the materials
    • D06N2209/10—Properties of the materials having mechanical properties
    • D06N2209/106—Roughness, anti-slip, abrasiveness

Definitions

  • the present invention relates to an apparatus for manufacturing of non-slip sheets for mats and a non-slip sheet manufactured by the same.
  • the non-slip sheet of the invention has a dual non-slip pattern in a forming region thereof.
  • a mat is spread on an indoor floor of a vehicle, house, vessel, airplane or train, or a floor of an entrance or a corridor of a building, in particular, on which a basic nonwoven cloth or a carpet raw material is laid (hereinafter referred to as "floor") .
  • the mat may be made of a single material, it mainly uses a cushion sheet such as basic nonwoven cloth and carpet in an upper layer, which is generally exposed to the outside, and a base sheet underlying the cushion sheet and contacts the floor. Protrusions of a specific configuration are formed in base sheet regions contacting the floor to prevent slippage of the mat from the floor.
  • this apparatus and method produces sheets at a very low rate by using a so-called Rotocure apparatus, that is, a heat drum to daily output a mat product of only about 1.5km and only a first protrusion pattern formed in the mat product.
  • Rotocure apparatus that is, a heat drum to daily output a mat product of only about 1.5km and only a first protrusion pattern formed in the mat product.
  • the present invention has been made in view of the foregoing problems and it is an object of the present invention to provide an apparatus for manufacturing of non-slip sheets for mats which have improved acuteness at ends of protrusions and a subsidiary protrusion pattern at the ends of the protrusions in order to enhance non-slipping properties of a mat with respect to a floor of a vehicle interior, entrance of a building or corridor of a building as well as increase daily yield about 4 to 5 times over a conventional one.
  • FIG. 1 is a conceptual view schematically illustrating an apparatus for manufacturing of non-slip sheets for mats according to a preferred embodiment of the invention
  • Fig. 2 is a magnified sectional view of an important part according to the preferred embodiment of the manufacturing apparatus of non-slip sheets for mats shown in Fig. 1;
  • Fig. 3 is an exploded perspective view of the forming roller and the forming member shown in Fig. 2;
  • Fig. 4 is a longitudinal sectional view of an assembly of the forming roller and the forming member shown in Fig. 2;
  • Figs. 5A and 5B are conceptual views illustrating subsidiary non-slip patterns of the forming roller shown in Figs. 3 and 4 ;
  • Figs. 6A and 6B are conceptual views illustrating main non-slip patterns of the forming member shown in Figs. 3 and 4;
  • Figs. 7A and 7B are plan views of examples of non-slip patterns in surfaces of sheets for mats produced by manufacturing apparatuses of sheets for mats according to preferred embodiments of the invention.
  • Fig. 8 is a magnification of Fig. 7A.
  • an apparatus for manufacturing of non-slip sheets for mats comprising : a mixing unit 10 for weighing and mixing raw material such as elastic amorphous resin having viscosity and rollability with respect to a roll, wherein examples of the raw material include Styrene-Butadiene-Styrene (SBS) , Thermoplastic Olefine (TPO) , Thermoplastic Elastomer (TPE) , Polyvinyl Chloride (PVC) and so on; a kneading unit 20 having an extruder for removing foreign materials from the raw material and melting the raw material, a pair of rollers for kneading the raw material and rollers for rolling the melted raw material; a calendaring unit 30 having a plurality of rollers for forming the raw material from the kneading unit 20 into a sheet of a predetermined thickness and width; an embossing unit 40 including a base roller rotat
  • the sheet includes: a formable base sheet made of amorphous resin having roll viscosity and elasticity, wherein the base sheet is processed to a predetermined temperature with the mixing unit, the kneading unit and the calendaring unit in the calendaring line; and a cushion sheet which is fed toward the nip and laminated on the base sheet through a feeding roller mounted on the frame separate from the calendaring line.
  • the subsidiary non-slip pattern is formed on the surface of the forming roller continuously along a longitudinal direction of the forming roller in the form of a cross or letter X, and the main non-slip pattern includes a plurality of holes spaced apart from one another to a predetermined interval and having a crossed or diamond-like cross section.
  • the forming member includes a cylinder which is arranged to surround the outer periphery of the forming roller and maintain a minute gap from the outer periphery of the forming roller having the recesses so that the cylinder can rotated along with the forming roller.
  • a non-slip sheet for mats comprising: a formable base sheet; a thermoplastic cushion sheet laminated on one surface of the base sheet, and made of fabric such as a carpet or nonwoven cloth; a main pattern having a number of main protrusions formed on the other surface of the base sheet which is formed by sequentially mixing, kneading, calendaring, cooling and winding elastic amorphous resin having viscosity and rollability with respect to a roll, examples of the raw material including Styrene-Butadiene-Styrene (SBS) , Thermoplastic Olefine (TPO) , Thermoplastic Elastomer (TPE) , Polyvinyl Chloride (PVC) and so on, wherein each of the main protrusions includes a uniform portion of a substantially uniform width having a crossed or diamond-like cross section projected by a predetermined length from the bottom surface of the base sheet and an enlarged portion having a width larger
  • SBS Styrene-But
  • Fig. 1 is a conceptual view schematically illustrating a manufacturing apparatus of non-slip sheets for mats according to a preferred embodiment of the invention.
  • the manufacturing apparatus of non-slip sheets for mats is aimed to minimize slippage of a mat to an indoor floor of a vehicle, house, vessel, airplane or train, or a floor of an entrance or a corridor of a building, in particular, on which a nonwoven cloth or a carpet raw material -is basically laid (hereinafter will be referred to as "floor") .
  • the manufacturing apparatus 100' comprises an embossing unit 40 modified from a typical embossing unit of a calendaring line, preceding process units including a mixing unit 10, a kneading unit 20 and a calendar unit 30 and following process units including a cooling unit 50 and a winding unit 60.
  • the mixing unit 10 includes a measuring instrument 12 for weighing raw material such as elastic amorphous resin having viscosity and rollability with respect to a roll, in which examples of the raw material may include Styrene-Butadiene-Styrene (SBS) , Thermoplastic define (TPO) , Thermoplastic Elastomer (TPE) , Polyvinyl Chloride (PVC) and so on, and a mixer 14 for mixing the raw material together with any additional raw material and preliminarily or primarily kneading the mixed raw material .
  • SBS Styrene-Butadiene-Styrene
  • TPO Thermoplastic define
  • TPE Thermoplastic Elastomer
  • PVC Polyvinyl Chloride
  • the kneading unit 20 includes an extruder 22 functioning to remove any foreign materials from the mixed raw material while melting the mixed raw material, a pair of rollers 24 for secondly kneading the raw material and rollers 26 for uniformly rolling the molten raw material.
  • the mixed calendar unit 30 includes a plurality of rollers 32 for forming the raw material from the kneading unit 20 into a sheet of a predetermined thickness and width, that is, in order to determined drawing properties of a final product.
  • the embossing unit 40 generally functions to impart luster or a certain pattern to the surface of the sheet in the calendaring line. However, according to the invention, the embossing unit 40 is modified to form a non-slip pattern in the surface of the sheet (in particular, a base sheet) .
  • the embossing unit 40 will be described in detail later.
  • the cooling unit 50 functions to cool the surface of a gelled product thereby solidifying the same.
  • the laminated sheet for mats is cooled while passing through the rollers 52, which are internally fed with cooling water.
  • the winding unit 60 serves to wind the completed sheet for mats around a winding roller 62.
  • Fig. 2 is a magnified sectional view of an important part (i.e., the embossing unit ) according to the preferred embodiment of the manufacturing apparatus of non-slip sheets for mats shown in Fig. 1.
  • the embossing unit includes a base roller 120 which is rotatably mounted on a frame 101 (refer to Fig.
  • a forming roller 130 rotatably mounted on the frame 101 in such a manner as to be spaced apart from the base roller 120 to a predetermined interval and having recesses in the surface thereof and a forming member 140 arranged in the outer periphery of the forming roller 130 to define a nip N (refer to Fig. 4) with the base roller 120.
  • the sheet-feeding unit 110 serves to continuously feed the sheet 112, which is heated to a predetermined temperature toward the nip N.
  • the sheet 112 may be made of a formable single material
  • the sheet 112 of this embodiment is separated into a base sheet 114 which is fed from the calendar unit 30 where the base sheet 114 is formably pre-processed and a cushion sheet 116 which is laminated on the base sheet 114.
  • the base sheet 114 is rolled through the calendar unit 30 under predetermined temperature conditions to have a predetermined percentage of elongation
  • the cushion sheet 116 is a stock material made of nonwoven cloth or carpet which is previously prepared so that the cushion sheet 116 can be unwound from a cushion roller 118.
  • Fig. 3 is an exploded perspective view of the forming roller and the forming member shown in Fig. 2
  • Fig. 4 is a longitudinal sectional view of an assembly of the forming roller and the forming member shown in Fig. 2.
  • the recessed forming roller 130 includes a rotary shaft 132 mounted on the frame 101, a hollow cylindrical roller 131 which is integrally mounted on the rotary shaft 132 and has a subsidiary non-slip pattern 134 formed on the surface thereof and a hollow structure with an open end 136 and a closed end 138, a cooling water pipe 133 arranged within the cylindrical roller 131 for feeding cooling water into the cylindrical roller 131. Cooling water fed via the cooling water pipe 133 is discharged via the open end 136 and received in a discharge bucket (not shown) before discharged.
  • the cooling water pipe 133 may be arranged within the rotary shaft 132, which is provided with a cooling water outlet.
  • the subsidiary non-slip pattern 134 is obtained in the form of crosses or Xs continued with respect to the length of the forming roller 130.
  • the surface of the forming roller 130 in Fig. 3 is an example of the cross-type non-slip pattern in Fig. 5A.
  • the forming member 140 is in the form of a cylinder having a predetermined thickness .
  • the forming member 140 has a plurality of through holes 142 for allowing passage of at least a portion of the base sheet 114.
  • the forming member 140 maintains a minute gap G (refer to Fig. 4) from the outer periphery of the forming roller 130 having the through holes, and is arranged to surround the outer periphery of the forming roller 130 and rotate along with rotation of the forming roller 130.
  • the forming roller 130 is provided with recesses or grooves, and both the recesses and the gap G act as spaces for guiding and discharging the flow of the surrounding air to the outside when the base sheet 114 passes through the through holes 142 of the forming member 140.
  • the forming member 140 may be fixed by both ends to the forming roller 130 via special welding, pressing against the forming roller 130, or fastening members (not shown) .
  • the non-slip pattern 144 is constituted of the plurality of through holes having a crossed or diamond-type cross section, which are spaced apart from one another to a predetermined interval.
  • Figs. 3 and 4 illustrate the through holes of the diamond cross-section. Referring to Figs. 2 through 4, at the nip N, surface portions of the base sheet 114 form a number of main protrusions 152 wider than the mean width of the through holes 142 while passing through ends of the through holes 142 of the main non-slip pattern 144, and the subsidiary non-slip pattern 134 forms sub-protrusions 154 in surfaces of the main protrusions 152.
  • the base sheet 114 is continuously fed toward the nip N of the embossing unit 40.
  • the cushion sheet 116 unwound from the cushion roller 118 is also continuously fed toward the nip N of the embossing unit 40.
  • the base sheet 114 and the cushion sheet 116 fed to the nip N are laminated on each other to form a laminated sheet.
  • portions of the base sheet 114 which are not laminated on the cushion sheet 116 pass through the through holes 142 of the non-slip pattern 144.
  • the portions of the base sheet 114 are elongated along the direction of air flow. Then, elongated portions of the base sheet 114 are formed as the main protrusions 152 having a mean width larger than the mean width of the through holes 142.
  • the portions of the base sheet 114 are subsequently introduced into the recesses of the subsidiary non-slip pattern 134 formed on the surface of the forming roller 130, thereby forming sub-protrusions 154 in the surfaces of the main protrusions 152. Since the forming roller 130 is cooled by cooling water which is fed via the cooling water pipe 133 to the inside of the forming roller 130, the base sheet 114 provided with the main protrusions 152 and the sub-protrusions 154 get out of the nip N instead of sticking to the forming roller 130 and the forming member 140 which are rotating.
  • the laminated sheet 150 is carried toward the cooling unit 50.
  • the sheet 150 laminated through the embossing unit 40 is cooled again by the cooling unit 50 to further cure the non-slip pattern formed on the surface of the sheet 150. Then, the laminated sheet 150 is finally wound around the winding roller 62.
  • Figs. 7A and 7B are plan views illustrating surfaces, that is, examples of non-slip patterns in base sheet surfaces of final sheet products produced by the manufacturing apparatus of sheets for mats, and Fig. 8 is a magnification of Fig. 7A.
  • the non-slip sheet 150 the non-slip sheet 150 for mats produced by the manufacturing apparatus of sheets for mats according to the preferred embodiment of the invention includes a main pattern 156 having the main protrusions 152 projected perpendicularly from one face of the base sheet 114 and a sub-pattern 158 having the sub-protrusions 154 projected perpendicularly from the surfaces of the protrusions 152 of the main pattern 156.
  • Each of the main protrusions 152 is of a diamond-type cross section, and includes a uniform section 152a projected from a bottom of the base sheet 114 to a predetermined length at a substantially uniform width W x and ah enlarged section 152b formed at the leading end of the uniform section 152a at a width W 2 larger than the mean width W x of the uniform section 152a.
  • the sub-pattern 158 includes the sub-protrusions 154, each of which has a continuous cross-type structure (refer to
  • Fig. 7A or a continuous X-like structure (Refer to Fig. 7B) .
  • the enlarged sections 152b of the main protrusions 152 and the sub-protrusions 154 of the sub-pattern 158 maximize the interference between the mat and the nonwoven cloth thereby minimizing the slippage of the mat from the nonwoven cloth.
  • the manufacturing apparatus of non-slip sheets for mats is not restricted to the foregoing embodiments.
  • the invention can be modified to a forming roller in a T-die line or in a Rotocure line.
  • the manufacturing apparatus of non-slip sheets for mats of the invention has a slow working speed, it can be applied to a press apparatus for fabricating high price mats.
  • the apparatus for manufacturing of non-slip sheets for mats of the invention produces sheets for mats by forming a subsidiary non-slip pattern in the surface of a forming roller and a main pattern on a cylindrical roller or forming belt which is in contact with the forming roller in order to have a productivity exceeding that of a conventional calendaring line. That is, the manufacturing apparatus of non-slip sheets for mats can have daily yield which is improved to about 6 to 8km a day. It is to be understood that the productivity is improved about 4 to 5 times over those of the prior art. Furthermore, the invention can ensure various non-slip patterns based upon subsidiary non-slip patterns of the forming roller and main non-slip patterns of the forming member to improve non-slipping properties of final sheet products .

Abstract

The present invention relates to an apparatus for manufacturing of non-slip sheets for mats and a non-slip sheet manufactured by the same. The manufacturing apparatus comprises: a base roller rotatably mounted on a frame to contact one surface of the sheet; a recessed forming roller rotatably mounted on the frame in such a manner as to be spaced apart from the base roller to a predetermined interval and having a subsidiary non-slip pattern formed on its surface for contracting the other surface of the sheet; and a forming member arranged to contact at least the outer periphery of the forming roller within a predetermined length of nip defined between the forming member and the base roller, and having main and subsidiary non-slip patterns of plurality of through holes so that surface portions of the sheet pass through the through holes to contact the surface of the forming roller. Each subsidiary pattern has a number of sub-protrusions and a continuous crossed or X-shaped cross section or projected from at least a surface portion of the each protrusion of the main pattern.

Description

APPARATUS FOR MANUFACTURING NON-SLIP SHEET FOR MAT AND IT' S THE USING
SHEET
Technical Field
The present invention relates to an apparatus for manufacturing of non-slip sheets for mats and a non-slip sheet manufactured by the same. In particular, the non-slip sheet of the invention has a dual non-slip pattern in a forming region thereof.
Background Art
In general, a mat is spread on an indoor floor of a vehicle, house, vessel, airplane or train, or a floor of an entrance or a corridor of a building, in particular, on which a basic nonwoven cloth or a carpet raw material is laid (hereinafter referred to as "floor") . Though the mat may be made of a single material, it mainly uses a cushion sheet such as basic nonwoven cloth and carpet in an upper layer, which is generally exposed to the outside, and a base sheet underlying the cushion sheet and contacts the floor. Protrusions of a specific configuration are formed in base sheet regions contacting the floor to prevent slippage of the mat from the floor. However, in conventional apparatuses and methods for forming the protrusions, ends of the protrusions are rounded instead of being acutely angled so that the protrusions do not have excellent frictional force against basic nonwoven cloth and so on, thereby failing to show a desirable result. In particular, though there have been carried out a number of studies on a vehicular mat related to an improvement of non-slipping properties of the mat, any satisfactory results have not been made so . far. As a technique to solve the above problems, Korean Patent Laid-Open Publication No. 2001-105796, entitled "Ma t Having Protrusions in Bottom and Method and Appara tus for Fabrica ting the Same ", was published. However, this apparatus and method produces sheets at a very low rate by using a so-called Rotocure apparatus, that is, a heat drum to daily output a mat product of only about 1.5km and only a first protrusion pattern formed in the mat product. As a result, there has been a problem in that the mat product does not have excellent non-slipping properties.
Disclosure of Invention
Therefore, the present invention has been made in view of the foregoing problems and it is an object of the present invention to provide an apparatus for manufacturing of non-slip sheets for mats which have improved acuteness at ends of protrusions and a subsidiary protrusion pattern at the ends of the protrusions in order to enhance non-slipping properties of a mat with respect to a floor of a vehicle interior, entrance of a building or corridor of a building as well as increase daily yield about 4 to 5 times over a conventional one.
It is another object of the invention to provide a non-slip sheet for mats which has a subsidiary protrusion pattern at ends of protrusions which is formed by a subsidiary non-slip pattern in a cylindrical roller to improve non-slip properties and enhance daily mean yield to about 6 to 8km, thereby improving price competitiveness.
Brief Description of the Drawings Further objects and advantages of the invention can be more fully understood from the following detailed description taken in conjunction with the accompanying drawings in which: Fig. 1 is a conceptual view schematically illustrating an apparatus for manufacturing of non-slip sheets for mats according to a preferred embodiment of the invention;
Fig. 2 is a magnified sectional view of an important part according to the preferred embodiment of the manufacturing apparatus of non-slip sheets for mats shown in Fig. 1;
Fig. 3 is an exploded perspective view of the forming roller and the forming member shown in Fig. 2;
Fig. 4 is a longitudinal sectional view of an assembly of the forming roller and the forming member shown in Fig. 2;
Figs. 5A and 5B are conceptual views illustrating subsidiary non-slip patterns of the forming roller shown in Figs. 3 and 4 ;
Figs. 6A and 6B are conceptual views illustrating main non-slip patterns of the forming member shown in Figs. 3 and 4;
Figs. 7A and 7B are plan views of examples of non-slip patterns in surfaces of sheets for mats produced by manufacturing apparatuses of sheets for mats according to preferred embodiments of the invention; and
Fig. 8 is a magnification of Fig. 7A.
Best Mode for Carrying Out the Invention
According to an aspect of the invention, there is provided an apparatus for manufacturing of non-slip sheets for mats comprising : a mixing unit 10 for weighing and mixing raw material such as elastic amorphous resin having viscosity and rollability with respect to a roll, wherein examples of the raw material include Styrene-Butadiene-Styrene (SBS) , Thermoplastic Olefine (TPO) , Thermoplastic Elastomer (TPE) , Polyvinyl Chloride (PVC) and so on; a kneading unit 20 having an extruder for removing foreign materials from the raw material and melting the raw material, a pair of rollers for kneading the raw material and rollers for rolling the melted raw material; a calendaring unit 30 having a plurality of rollers for forming the raw material from the kneading unit 20 into a sheet of a predetermined thickness and width; an embossing unit 40 including a base roller rotatably mounted on a frame to contact one surface of the sheet for imparting luster or a certain pattern to the surface of the sheet in a calendaring line and a forming roller having recesses formed thereon, wherein the forming roller includes a rotary shaft rotatably mounted on the frame in such a manner as to be spaced apart from the base roller to a predetermined interval, a cylindrical roller having a subsidiary non-slip pattern ormed on its surface for contacting the other surface of the sheet and a cooling water pipe arranged within the cylindrical roller for feeding cooling water to the cylindrical roller; a cooling unit 50 for re-cooling the sheet which is laminated through the embossing unit 40; a winding unit 60 for winding the laminated sheet around a winding roller; and a forming member arranged to contact at least the outer periphery of the forming roller within a predetermined length of nip defined between the forming member and the base roller, and having main and subsidiary non-slip patterns of a plurality of through holes so that surface portions of the sheet pass through the through holes to contact the surface of the forming roller, whereby the surface portions of the sheet form a plurality of main protrusions of a mean width larger than that of the through holes while passing through ends of the through holes and sub-protrusions are formed on the surface of each of the main protrusions by the subsidiary non-slip pattern provided in the form of recesses in the surface of the forming roller.
In the manufacturing apparatus of non-slip sheets for mats according to the preferred embodiment of the invention, the sheet includes: a formable base sheet made of amorphous resin having roll viscosity and elasticity, wherein the base sheet is processed to a predetermined temperature with the mixing unit, the kneading unit and the calendaring unit in the calendaring line; and a cushion sheet which is fed toward the nip and laminated on the base sheet through a feeding roller mounted on the frame separate from the calendaring line.
In the manufacturing apparatus of non-slip sheets for mats according to the preferred embodiment of the invention, the subsidiary non-slip pattern is formed on the surface of the forming roller continuously along a longitudinal direction of the forming roller in the form of a cross or letter X, and the main non-slip pattern includes a plurality of holes spaced apart from one another to a predetermined interval and having a crossed or diamond-like cross section.
In the manufacturing apparatus of non-slip sheets for mats according to the preferred embodiment of the invention, the forming member includes a cylinder which is arranged to surround the outer periphery of the forming roller and maintain a minute gap from the outer periphery of the forming roller having the recesses so that the cylinder can rotated along with the forming roller.
According to another aspect of the invention, there is provided a non-slip sheet for mats comprising: a formable base sheet; a thermoplastic cushion sheet laminated on one surface of the base sheet, and made of fabric such as a carpet or nonwoven cloth; a main pattern having a number of main protrusions formed on the other surface of the base sheet which is formed by sequentially mixing, kneading, calendaring, cooling and winding elastic amorphous resin having viscosity and rollability with respect to a roll, examples of the raw material including Styrene-Butadiene-Styrene (SBS) , Thermoplastic Olefine (TPO) , Thermoplastic Elastomer (TPE) , Polyvinyl Chloride (PVC) and so on, wherein each of the main protrusions includes a uniform portion of a substantially uniform width having a crossed or diamond-like cross section projected by a predetermined length from the bottom surface of the base sheet and an enlarged portion having a width larger than a mean width of the uniform portion; and a subsidiary pattern having a number of sub-protrusions each has a continuous crossed or X-shaped cross section or projected from at least a surface portion of the each protrusion of the main pattern.
The following detailed description will present a manufacturing apparatus of non-slip sheets for mats according to a preferred embodiment of the invention in conjunction with the accompanying drawings. Fig. 1 is a conceptual view schematically illustrating a manufacturing apparatus of non-slip sheets for mats according to a preferred embodiment of the invention.
As shown in Fig.1, the manufacturing apparatus of non-slip sheets for mats according to the preferred embodiment of the invention is aimed to minimize slippage of a mat to an indoor floor of a vehicle, house, vessel, airplane or train, or a floor of an entrance or a corridor of a building, in particular, on which a nonwoven cloth or a carpet raw material -is basically laid (hereinafter will be referred to as "floor") . The manufacturing apparatus 100' comprises an embossing unit 40 modified from a typical embossing unit of a calendaring line, preceding process units including a mixing unit 10, a kneading unit 20 and a calendar unit 30 and following process units including a cooling unit 50 and a winding unit 60. The mixing unit 10 includes a measuring instrument 12 for weighing raw material such as elastic amorphous resin having viscosity and rollability with respect to a roll, in which examples of the raw material may include Styrene-Butadiene-Styrene (SBS) , Thermoplastic define (TPO) , Thermoplastic Elastomer (TPE) , Polyvinyl Chloride (PVC) and so on, and a mixer 14 for mixing the raw material together with any additional raw material and preliminarily or primarily kneading the mixed raw material .
The kneading unit 20 includes an extruder 22 functioning to remove any foreign materials from the mixed raw material while melting the mixed raw material, a pair of rollers 24 for secondly kneading the raw material and rollers 26 for uniformly rolling the molten raw material.
The mixed calendar unit 30 includes a plurality of rollers 32 for forming the raw material from the kneading unit 20 into a sheet of a predetermined thickness and width, that is, in order to determined drawing properties of a final product.
The embossing unit 40 generally functions to impart luster or a certain pattern to the surface of the sheet in the calendaring line. However, according to the invention, the embossing unit 40 is modified to form a non-slip pattern in the surface of the sheet (in particular, a base sheet) . The embossing unit 40 will be described in detail later.
The cooling unit 50 functions to cool the surface of a gelled product thereby solidifying the same. In the cooling unit 50, the laminated sheet for mats is cooled while passing through the rollers 52, which are internally fed with cooling water.
The winding unit 60 serves to wind the completed sheet for mats around a winding roller 62.
Fig. 2 is a magnified sectional view of an important part (i.e., the embossing unit ) according to the preferred embodiment of the manufacturing apparatus of non-slip sheets for mats shown in Fig. 1. As shown in Fig. 2, the embossing unit includes a base roller 120 which is rotatably mounted on a frame 101 (refer to Fig. 4) to contact one surface of a raw material sheet 112 fed from a sheet feeding unit 110, a forming roller 130 rotatably mounted on the frame 101 in such a manner as to be spaced apart from the base roller 120 to a predetermined interval and having recesses in the surface thereof and a forming member 140 arranged in the outer periphery of the forming roller 130 to define a nip N (refer to Fig. 4) with the base roller 120. The sheet-feeding unit 110 serves to continuously feed the sheet 112, which is heated to a predetermined temperature toward the nip N. Though the sheet 112 may be made of a formable single material, the sheet 112 of this embodiment is separated into a base sheet 114 which is fed from the calendar unit 30 where the base sheet 114 is formably pre-processed and a cushion sheet 116 which is laminated on the base sheet 114. The base sheet 114 is rolled through the calendar unit 30 under predetermined temperature conditions to have a predetermined percentage of elongation, and the cushion sheet 116 is a stock material made of nonwoven cloth or carpet which is previously prepared so that the cushion sheet 116 can be unwound from a cushion roller 118.
Fig. 3 is an exploded perspective view of the forming roller and the forming member shown in Fig. 2, and Fig. 4 is a longitudinal sectional view of an assembly of the forming roller and the forming member shown in Fig. 2.
As shown in Figs. 2 through 4, the recessed forming roller 130 includes a rotary shaft 132 mounted on the frame 101, a hollow cylindrical roller 131 which is integrally mounted on the rotary shaft 132 and has a subsidiary non-slip pattern 134 formed on the surface thereof and a hollow structure with an open end 136 and a closed end 138, a cooling water pipe 133 arranged within the cylindrical roller 131 for feeding cooling water into the cylindrical roller 131. Cooling water fed via the cooling water pipe 133 is discharged via the open end 136 and received in a discharge bucket (not shown) before discharged. Alternatively, the cooling water pipe 133 may be arranged within the rotary shaft 132, which is provided with a cooling water outlet.
The subsidiary non-slip pattern 134, as shown in Figs. 5A and 5B, is obtained in the form of crosses or Xs continued with respect to the length of the forming roller 130. The surface of the forming roller 130 in Fig. 3 is an example of the cross-type non-slip pattern in Fig. 5A.
Referring to Figs. 2 through 4 again, the forming member 140 is in the form of a cylinder having a predetermined thickness . The forming member 140 has a plurality of through holes 142 for allowing passage of at least a portion of the base sheet 114. The forming member 140 maintains a minute gap G (refer to Fig. 4) from the outer periphery of the forming roller 130 having the through holes, and is arranged to surround the outer periphery of the forming roller 130 and rotate along with rotation of the forming roller 130. The forming roller 130 is provided with recesses or grooves, and both the recesses and the gap G act as spaces for guiding and discharging the flow of the surrounding air to the outside when the base sheet 114 passes through the through holes 142 of the forming member 140. The forming member 140 may be fixed by both ends to the forming roller 130 via special welding, pressing against the forming roller 130, or fastening members (not shown) .
As shown in Figs. 6A and 6B, the non-slip pattern 144 is constituted of the plurality of through holes having a crossed or diamond-type cross section, which are spaced apart from one another to a predetermined interval. Figs. 3 and 4 illustrate the through holes of the diamond cross-section. Referring to Figs. 2 through 4, at the nip N, surface portions of the base sheet 114 form a number of main protrusions 152 wider than the mean width of the through holes 142 while passing through ends of the through holes 142 of the main non-slip pattern 144, and the subsidiary non-slip pattern 134 forms sub-protrusions 154 in surfaces of the main protrusions 152.
Hereinafter description will be made about the operation of the manufacturing apparatus of non-slip sheets for mats according to the preferred embodiment of the invention.
First, as shown in Fig. 1, after being formed to the predetermined thickness and width and heated to the predetermined temperature while passing through the mixing unit 10, the kneading unit 20 and the calendar unit 30, the base sheet 114 is continuously fed toward the nip N of the embossing unit 40. The cushion sheet 116 unwound from the cushion roller 118 is also continuously fed toward the nip N of the embossing unit 40.
Under the force between the forming member 140 and the base roller 120 which are rotating, the base sheet 114 and the cushion sheet 116 fed to the nip N are laminated on each other to form a laminated sheet. In the meantime, portions of the base sheet 114 which are not laminated on the cushion sheet 116 pass through the through holes 142 of the non-slip pattern 144. After passing through the through holes 142, as air flows out through the recesses formed on the outer periphery of the forming roller 130 and the forming member 140 and the minute gap G maintained between the outer periphery of the forming roller 130 and the forming member 140, the portions of the base sheet 114 are elongated along the direction of air flow. Then, elongated portions of the base sheet 114 are formed as the main protrusions 152 having a mean width larger than the mean width of the through holes 142.
After passing through the through holes 142 of the forming member 140, the portions of the base sheet 114 are subsequently introduced into the recesses of the subsidiary non-slip pattern 134 formed on the surface of the forming roller 130, thereby forming sub-protrusions 154 in the surfaces of the main protrusions 152. Since the forming roller 130 is cooled by cooling water which is fed via the cooling water pipe 133 to the inside of the forming roller 130, the base sheet 114 provided with the main protrusions 152 and the sub-protrusions 154 get out of the nip N instead of sticking to the forming roller 130 and the forming member 140 which are rotating. The laminated sheet 150 is carried toward the cooling unit 50. The sheet 150 laminated through the embossing unit 40 is cooled again by the cooling unit 50 to further cure the non-slip pattern formed on the surface of the sheet 150. Then, the laminated sheet 150 is finally wound around the winding roller 62.
Figs. 7A and 7B are plan views illustrating surfaces, that is, examples of non-slip patterns in base sheet surfaces of final sheet products produced by the manufacturing apparatus of sheets for mats, and Fig. 8 is a magnification of Fig. 7A.
As shown in Figs. 7A through 8, the non-slip sheet 150 the non-slip sheet 150 for mats produced by the manufacturing apparatus of sheets for mats according to the preferred embodiment of the invention includes a main pattern 156 having the main protrusions 152 projected perpendicularly from one face of the base sheet 114 and a sub-pattern 158 having the sub-protrusions 154 projected perpendicularly from the surfaces of the protrusions 152 of the main pattern 156. Each of the main protrusions 152 is of a diamond-type cross section, and includes a uniform section 152a projected from a bottom of the base sheet 114 to a predetermined length at a substantially uniform width Wx and ah enlarged section 152b formed at the leading end of the uniform section 152a at a width W2 larger than the mean width Wx of the uniform section 152a.
The sub-pattern 158 includes the sub-protrusions 154, each of which has a continuous cross-type structure (refer to
Fig. 7A) or a continuous X-like structure (Refer to Fig. 7B) .
Therefore, when a mat formed by cutting the non-slip sheet 150 in Fig. 8 is laid on a bottom made of a nonwoven cloth, the enlarged sections 152b of the main protrusions 152 and the sub-protrusions 154 of the sub-pattern 158 maximize the interference between the mat and the nonwoven cloth thereby minimizing the slippage of the mat from the nonwoven cloth.
Industrial Applicability While the present invention has been described with reference to an apparatus for manufacturing of non-slip sheets for mats according to the particular illustrative embodiments of the invention adopting a calendaring technique, the manufacturing apparatus of non-slip sheets for mats is not restricted to the foregoing embodiments. For example, the invention can be modified to a forming roller in a T-die line or in a Rotocure line.
Furthermore, although the manufacturing apparatus of non-slip sheets for mats of the invention has a slow working speed, it can be applied to a press apparatus for fabricating high price mats.
As set forth above, the apparatus for manufacturing of non-slip sheets for mats of the invention produces sheets for mats by forming a subsidiary non-slip pattern in the surface of a forming roller and a main pattern on a cylindrical roller or forming belt which is in contact with the forming roller in order to have a productivity exceeding that of a conventional calendaring line. That is, the manufacturing apparatus of non-slip sheets for mats can have daily yield which is improved to about 6 to 8km a day. It is to be understood that the productivity is improved about 4 to 5 times over those of the prior art. Furthermore, the invention can ensure various non-slip patterns based upon subsidiary non-slip patterns of the forming roller and main non-slip patterns of the forming member to improve non-slipping properties of final sheet products .

Claims

What Is Claimed Is:
1. An apparatus for manufacturing of non-slip sheets for mats comprising: a mixing unit (10) for weighing and mixing raw material such as elastic amorphous resin having viscosity and rollability with respect to a roll, wherein examples of the raw material include Styrene-Butadiene-Styrene (SBS) , Thermoplastic define (TPO) , Thermoplastic Elastomer (TPE) , Polyvinyl Chloride (PVC) and so on; a kneading unit (20) having an extruder for removing foreign materials from the raw material and melting the raw material, a pair of rollers for kneading the raw material and rollers for rolling the melted raw material; a calendaring unit (30) having a plurality of rollers for forming the raw material from the kneading unit (20) into a sheet of a predetermined thickness and width; an embossing unit (40) including a base roller rotatably mounted on a frame to contact one surface of the sheet for imparting luster or a certain pattern to the surface of the sheet in a calendaring line and a forming roller having recesses formed thereon, wherein the forming roller includes a rotary shaft rotatably mounted on the frame in such a manner as to be spaced apart from the base roller to a predetermined interval, a cylindrical roller having a subsidiary non-slip pattern formed on its surface for contacting the other surface of the sheet and a cooling water pipe arranged within the cylindrical roller for feeding cooling water to the cylindrical roller; a cooling unit (50) for re-cooling the sheet which is laminated through the embossing unit (40) ; a winding unit (60) for winding the laminated sheet around a winding roller; and a forming member arranged to contact at least the outer periphery of the forming roller within a predetermined length of nip defined between the forming member and the base roller, and having main and subsidiary non-slip patterns of a plurality of through holes so that surface portions of the sheet pass through the through holes to contact the surface of the forming roller, whereby the surface portions of the sheet form a plurality of main protrusions of a mean width larger than that of the through holes while passing through ends of the through holes and sub-protrusions are formed on the surface of each of the main protrusions by the subsidiary non-slip pattern' provided in the form of recesses in the surface of the forming roller.
2. The apparatus as set forth in claim 1, wherein the sheet includes : a formable base sheet made of amorphous resin having roll viscosity and elasticity, wherein the base sheet is processed to a predetermined temperature with the mixing unit, the kneading unit and the calendaring unit in the calendaring line; and a cushion sheet which is fed toward the nip and laminated on the base sheet through a feeding roller mounted on the frame separate from the calendaring line.
3. The apparatus as set forth in claim 1, wherein the subsidiary non-slip pattern is formed on the surface of the forming roller continuously along a longitudinal direction of the forming roller in the form of a cross or letter X, and the main non-slip pattern includes a plurality of holes spaced apart from one another by predetermined intervals and having a crossed or diamond-like cross section.
4. A non-slip sheet for mats comprising: a formable base sheet; a thermoplastic cushion sheet laminated on one surface of the base sheet, and made of fabric such as a carpet or nonwoven cloth; a main pattern having a number of main protrusions formed on the other surface of the base sheet which is formed by sequentially mixing, kneading, calendaring, cooling and winding elastic amorphous resin having viscosity and rollability with respect to a roll, examples of the raw material including Styrene-Butadiene-Styrene (SBS) , Thermoplastic define (TPO) , Thermoplastic Elastomer (TPE) , Polyvinyl Chloride (PVC) and so on, wherein each of the main protrusions includes a uniform portion of a substantially uniform width having a crossed or diamond-like cross section projected by a predetermined length from the bottom surface of the base sheet and an enlarged portion having a width larger than a mean width of the uniform portion; and a subsidiary pattern having a number of sub-protrusions each has a continuous crossed or X-shaped cross section or projected from at least a surface portion of the each protrusion of the main pattern.
PCT/KR2003/001194 2003-04-30 2003-06-19 Apparatus for manufacturing non-slip sheet for mat and it’s the using sheet WO2004095990A1 (en)

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JP2006513802A (en) 2006-04-27
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CN1658779A (en) 2005-08-24

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