JP2617401B2 - Manufacturing method of mud drop mat - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a a method for manufacturing the mud off mats provided with a surface layer or both sides to the decorative pattern or slip layer of the mat formed by the loop group of a large number of synthetic resin monofilament is there.

[0002]

BACKGROUND ART Conventionally, Sri Thus a number of synthetic resin monofilament scraping mat loop group Ru is formed by deposition of, or provided with a decorative pattern on the surface, further to the back surface
It is known that the anti-slip layers are provided in a pattern .

[0003]

However, this is not the case.
To produce a slushy mat, it is deposited in a loop
For example, Japanese Patent Application Laid-Open
Apply an adhesive and heat as shown in
A step of drying and further cooling was required.
Also, to give a decorative pattern to the surface of the mat, for example,
As disclosed in Japanese Patent Application Laid-Open No. 4-144532,
And display it by welding.
Step of fusing low-melting fibers as in No. 76
Adds complexity to the manufacturing process and
It is difficult to produce efficiently by such a process.
Therefore, an object of the present invention is to solve such problems .
And to provide a good manufacturing process efficient mud off mats.

[0004]

According to the method of the present invention, a cooling water tank is provided below an extruder provided with a spinning pack having a plurality of rows of nozzles arranged at different positions. A forming roll with a concave groove on the peripheral surface inside
Along with a pattern forming roll having an arbitrary pattern protruding on the peripheral surface, a part of the peripheral surface of the pattern forming roll is covered with a convection suppressing cover, and a large number of synthetic resin monofilaments are drooped from each of the nozzles. portion thereof let me receiving looped <br/> groove of the forming roll periphery surface brought form accompanied not slip layer to the rotation of the molding roll, another part of the monofilament the slip Te The back layer is formed by receiving in the form of a loop on the surface of the prevention layer and the forming roll, and the remaining monofilament is received on the water surface lower than the surface of the forming roll to form a surface layer in a loop on the back layer. At the same time, a decorative pattern is formed on the surface by a pattern forming roll, and the loops are fused and bonded to each other at intersections to form an integrated mat.

[0005] In addition, it is used for floor surfaces that do not require slip prevention.
If you want to manufacture a mat to use, the circumference table for molding the Ma Tsu door
Forming roll with flat groove on the peripheral surface
By replacing the roll and molding, the back side of the mat
Each loop is fused and bonded in a flat state
To configure

[0006]

[Function] The molten monofilament extruded from each nozzle hangs down and is received in a loop on the peripheral surface of the forming roll.
And a groove is provided on the peripheral surface of the forming roll.
In the case, the anti-slip layer is projected and formed, and the peripheral surface of the forming roll
If the mat is flat, form a mat without an anti-slip layer.
The decorative pattern on the surface is then
It is formed. Furthermore, the loops are mutually reciprocated at each intersection.
Self-fusing to combine and integrate.

[0007]

An embodiment of the present invention will be described below with reference to the drawings. In FIG. 1, reference numeral 1 denotes an extruder for melting and extruding a soft vinyl chloride resin. A spinning pack 2 is connected to the tip of the extruder, and nozzles (not shown) are displaced from each other below the spinning pack 2. Three rows are arranged, and rows F1 to F3 of monofilaments spun from these nozzles are drooped straight. The rows of these monofilaments are
There was formed a slip layer S of the mat, central F2 forms the back surface layer L of the mat, F3 after close is possible to form the surface layer A of the mat.

Reference numeral 3 denotes a row F1 of each of these monofilaments.
To forming a loop in each of F3 to F3,
Go Release eyes shaped groove as shown in FIG. 2 on the peripheral surface 4, 4
Is provided below the spinning pack 2 and rotated in the direction of the arrow. Reference numeral 5 denotes a pattern forming roll which is installed so as to rotate in the direction of the arrow shown in FIG. 1 in opposition to the forming roll 3, and has a ridge 6 of an arbitrary design provided on the peripheral surface thereof as shown in FIG. Form. The pattern forming roll 5 has a structure in which the distance between the shaft and the forming roll 3 is adjusted according to the ridge 6. Reference numeral 7 denotes a guide roll of a mat sent out from a pair of a forming roll 3 and a pattern forming roll 5, which is positioned and installed so that the mat can be moved vertically, and rotated in a direction indicated by an arrow shown in FIG. 8 is a delivery roll.

Reference numeral 9 denotes a cooling water tank containing the forming roll 3, the pattern shaping roll 5 and the guide roll 7, in which cooling water having a constant temperature (50 ° C. to 60 ° C.) is stored. The temperature of the cooling water is set to such a level that the monofilaments F1 to F3 spun from the nozzles of the spinning pack 2 are gradually cooled without being rapidly cooled, so that a uniform loop group is formed. . An outflow pipe 10 communicating with the inside is provided at an upper part of one side wall of the cooling water tank 9, and an inflow pipe 11 is similarly provided at a lower part. The outflow pipe 10 and the inflow pipe 11 are connected via a circulation pump 12 and a hot water heater 13, and further connected to a water supply pipe 15 provided with a cold water supply valve 14 behind the hot water heater 13.
Reference numeral 16 denotes another side of the cooling water tank 9, which is a water temperature controller arranged so that a detection part at a lower end is immersed in water, and is electrically connected to the hot water heater 13 and the cold water supply valve 14. For example, when the temperature of the cooling water becomes lower than a predetermined temperature, a signal is sent from the water temperature controller 16 to the hot water heater 13, and when the hot water heater 13 generates heat, the circulation pump 12 is operated and the inside of the cooling water tank 9 is activated. Of water from the lower inlet pipe 11,
The hot water heated to a predetermined temperature by passing through the hot water heater 13 flows out from the upper outlet pipe 10. However, in this case, the cold water supply valve 14 is closed.

When the cooling water becomes higher than a predetermined temperature,
A signal is sent from the water temperature controller 16 to the chilled water supply valve 14, and when the chilled water supply valve 14 is opened, the circulation pump 12 is operated and the chilled water sent from the water supply pipe 15 flows out of the outflow pipe 10. . A heat source in this case hot water heater 13
Turned off . In this way, the water temperature of the cooling water tank 9 is always kept almost constant. In addition, the water surface 17 of the cooling water is adjusted to have a predetermined height below the nozzle surface .

A convection suppressing cover 18 is provided along the peripheral surface of the pattern forming roll 5 so as to cover a portion of the cooling water from underwater to slightly above the water surface 17. The convection control cover 18, the temperature of the pattern forming roll 5 and retained so as not rapidly cooled by the cooling water, decorative pattern D and scan
Adjust the water temperature to ensure that the lip prevention layer S is formed
I have.

[0012] Of the monofilament rows sent out from the spinning pack 2, F1 hangs down from the forming rolls 3.
To form a small annular continuous loop L1 while accumulating in the concave groove 4 provided on the peripheral surface of the forming roll 3,
Loop each other adjacent the fused with each intersection to form an anti-slip layer S forming the go board eyes shape as a whole not with the rotation of the molding roll 3. Thus the formed entire surface of the molding roll 3, including a slip layer S by hanging a row of monofilament F2, to form a loop L2, the intersection of the loop L1 of the loop L2 and the slip layer S There fused to form a backside layer L further intersections are fused each loop L2 monofilaments F2, not with the rotation of the molding roll 3 at a high temperature of fusible Jo <br/> state water surface 17 Is transferred to

On the other hand, a row of monofilaments F3 hangs down on the water surface 17 near this position, and a loop L3 larger than the loops L1 and L2 formed by the rows of monofilaments F1 and F2 hanging on the water surface 17 is formed. Then, these loops L3 overlap with the loops L2 of the back layer L and are fused at intersections to form the surface layer A of the mat, and the surface of the surface layer A is br /> rib 6 provided on the pressing by the circumferential surface of the該模like forming roll 5
To form the decorative pattern D. The mat is then is fed moved into water loop L3 of the surface layer A is fixed by deformation is gradually cooled in water, becomes a three-dimensional complex curved shape, scraping the shape shown in FIGS. 4 to 6 A mat M is formed.

As shown in these drawings, loops L1 to L3 formed by rows F1 to F3 of each monofilament.
The size of 3 is such that the shorter the length of each droop to reach the forming roll 3 having a curved surface, the smaller the loop diameter becomes, so that the loop diameter L1 of the anti-slip layer S is minimized, and Is the loop diameter L larger than the anti-slip layer S
Make 2 Further, since the hanging distance of F3 forming the surface layer A is up to the water surface 17, it is the longest, and the maximum loop diameter is formed. Then, by slightly changing the mounting height of the forming roll 3 and the height of the water surface 17, the loop diameter L1
It is possible to easily change the size and shape of L3, and furthermore, the rising angle of the loop L3 of the surface layer A, so that mats having different structures can be manufactured.

[0015] The mud drop mat M thus produced is
Surface layer A as shown in FIG. 4 may form a three-dimensional three-dimensional curves, yet exhibits a novel appearance by decorative pattern D for any uneven pattern is formed on the surface thereof. The functions of cleat sole as shown in FIG. 7 is increased since the uneven pattern is formed, also written凹模like part of the shoe
Rubs with the slab to reliably capture a large amount of mud and increase the mud dropping function. Further, since the space portion 19 between the back layer L and the anti-slip layer S is formed, excellent performance for trapping cushioning good mud trapped mud falls through the backside layer L, Go Anti-slip layer S with square shape
Reservoir to fall within the and be scattered mud that go board eyes has accumulated becomes weir to the outside of the mud off the mat M
Because there is no mud, the area around the mud drop mat M is not stained with mud.

FIG. 8 shows a molding roller formed by forming a concave groove 4 on the peripheral surface by the molding roll 3 described in FIG.
Take replacement Ete, forming roll 3 formed in the circumferential surface of the flat
FIG. 2 is an example using a, and is a schematic structural diagram of an apparatus configured similarly to FIG. 1 except for a forming roll 3a . By manufacturing a mat using this apparatus, a decorative pattern D of an arbitrary pattern is formed only on the surface layer A as shown in FIG.
', The anti-slip layer S is required.
Used for floors that are not needed.

[0017]

As described above, according to the method for producing a mud drop mat of the present invention, a synthetic resin monofilament is formed by a molding method.
Loops on the peripheral surface of the
Excellent in strength, self-fused and joined at each intersection
A mat is formed. And the concave groove provided in the forming roll
Anti-slip layer is integrally formed on the mud-off mat
Mat that does not require an anti-slip layer.
When forming, form a roll with concave grooves on a flat
A roll without an anti-slip layer only by replacing
Is formed, so the presence or absence of an anti-slip layer can be freely selected.
Continuously and efficiently manufacture the selected mud
Can be.

[Brief description of the drawings]

FIG. 1 is a schematic structural view of an apparatus for manufacturing a mud drop mat.

FIG. 2 is a perspective view of a forming roll.

FIG. 3 is a perspective view of a pattern forming roll.

FIG. 4 is a perspective view of a mud drop mat.

FIG. 5 is a partially enlarged side view of the above.

FIG. 6 is a rear perspective view of FIG. 4;

FIG. 7 is a partially enlarged sectional view showing a use state of the mud drop mat.

FIG. 8 is a schematic structural diagram of an apparatus for manufacturing a mud-drop mat in which the peripheral surface of a forming roll is formed flat.

FIG. 9 is a perspective view of a mud drop mat M ′ manufactured by the apparatus of FIG. 8;

[Explanation of symbols]

REFERENCE SIGNS LIST 1 extruder 2 spinning pack 3, 3 a forming roll 4 concave groove 5 pattern forming roll 6 ridge 9 cooling water tank 18 convection suppressing cover A surface layer D decorative pattern F1 to F3 monofilament L back layer L1 to L3 loop M, M ′ Mud drop mat S Anti-slip layer

Claims (2)

(57) [Claims] 1. A forming roll provided with a cooling water tank below an extruder provided with a spinning pack having a plurality of rows of nozzles displaced from each other, and provided with a concave groove on a peripheral surface in the cooling water tank .
Along with a pattern forming roll having an arbitrary pattern protruding on the peripheral surface, a part of the peripheral surface of the pattern forming roll is covered with a convection suppressing cover, and a large number of synthetic resin monofilaments are drooped from each of the nozzles. portion thereof let me receiving looped <br/> groove of the forming roll periphery surface brought form accompanied not slip layer to the rotation of the molding roll, another part of the monofilament the slip Te The back layer is formed by receiving the prevention layer and the surface of the forming roll in a loop form, and the remaining monofilament is received on a lower water surface than the surface of the forming roll to form a loop surface layer on the back layer. A mud drop mat, wherein a decorative pattern is formed on the surface thereof by a pattern shaping roll, and the loops are fused and bonded to each other at intersections to form an integrated mat. Manufacturing method. 2. A forming roll having a concave groove on the peripheral surface is provided on a peripheral surface.
Configuration replaced with a forming roll with a flat surface
The method for producing a mud-shedding mat according to claim 1, comprising: