JP3406864B2 - Method and apparatus for manufacturing mats with characters and patterns - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention is laid to remove mud such as shoes at a doorway of a building or a room in the building,
The present invention relates to a method and an apparatus for manufacturing a mat with characters / designs on which various characters and designs are displayed.

[0002]

2. Description of the Related Art Conventionally, for example, the following method has been used to manufacture this type of mat. That is, first, a synthetic resin filament is extruded to form a three-dimensional loop layer, and a sheet is integrally attached to the back surface thereof to form a so-called mat-like object 100 (FIG. 10 (1)). Cut the required size into a mat 1 of a specified size
01 (FIG. 10 (2)) is molded. And the mat 1
01 is pressed by a high-frequency press machine to form a recess 102 (FIG. 10) having the same shape as a desired character / design on the surface of the mat 101.
(3)) is recessed.

On the other hand, a foamed vinyl chloride sheet 103 (FIG. 10 (4)) of a color different from that of the mat 101 is molded,
This is cut into an appropriate size (FIG. 10 (5)), and a character / design having the same contour as the recess 102 is punched from this (FIG. 10 (6)) to form a punching piece 104. Therefore, a punching piece 104 that manually matches with each depression 102 on the surface of the mat 101, for example, a punching piece 104 of "A" character is inserted into the depression 102 of "A" character (FIG. 10).
(7)), in this state, the high-frequency press machine again presses each recess 102 to press each punching piece 104 in each recess 102.
The mat M with letters and patterns is formed by melt-pressing.

[0004]

As described above, in the conventional method for producing a mat with characters / designs, the mat 10 is used.
Each punching piece 104 must be manually inserted into each recess 102 on one surface, which requires a lot of troublesome work. In addition, high-frequency press processing is performed before and after inserting the punching piece 104. The manufacturing process was complicated by repeating twice and, which was one of the factors that hindered the improvement of production efficiency. Therefore, the present invention has been made to solve the above problems, and an object of the present invention is to provide a method and apparatus for manufacturing a mat with characters / designs, in which the production efficiency is significantly improved by simplifying the manufacturing process. To do.

[0005]

In order to achieve such an object, the method for producing a mat with characters / patterns according to the present invention,
A mat is placed on the upper surface of the lower molding board, and a heat-meltable bonding resin sheet provided so that the letters and patterns can be separated at a predetermined position on the upper surface of the mat is positioned and arranged by a holding member, and then the upper molding board. To lower the letters on the laminated resin sheet
The design was melt-pressed onto the surface of the mat by high-frequency pressing. In this way, the heat-fusible bonding resin sheet provided so that the characters and patterns can be separated at a predetermined position on the upper surface of the mat is positioned and arranged by the holding member, and the upper molding board is lowered to move the characters and characters of the bonding resin sheet. Since the design is melt-pressed on the mat surface by high-frequency pressing, it is not necessary to fit the punched piece into the recess by hand one by one as in the past, and high-frequency pressing is only required once, so it is extremely efficient. We can produce mats with letters and patterns.

In carrying out the above-mentioned manufacturing method, the apparatus for manufacturing a mat with characters / designs according to the present invention is, for example, a lower molding board on which the mat is placed, and a high-frequency press for freely contacting and separating the lower molding board. It consists of an upper molding board having a molding die for processing, on the upper surface of the lower molding board, a fixing jig arranged so as to be freely detachable along the outer peripheral edge of the placed mat, And a holding member for engaging with the fixing jig and holding the heat-fusible laminating resin sheet provided so that characters and patterns can be separated, and for arranging it at a predetermined position on the upper surface of the mat. It

[0007]

BEST MODE FOR CARRYING OUT THE INVENTION Embodiments of a method for manufacturing a mat with characters / designs and an apparatus therefor according to the present invention will be described below with reference to the drawings. First, an apparatus for producing a mat with letters and / or patterns according to the present invention will be described. The apparatus is provided with a lower forming board W1 and is arranged above the lower forming board W1 as shown in FIG. It comprises an upper forming board W2 which freely comes in contact with and separates from the upper surface of the lower forming board W1. Lower forming board W
1, a high-frequency molding lower mold fixing plate 2 is placed on the upper surface of a planar rectangular high-frequency heating lower plate 1, and a rectangular frame-shaped peripheral molding lower mold 3 is placed on the upper surface of the high-frequency molding lower mold fixing plate 2. And the character / pattern forming lower support plate 4 is placed inside the peripheral forming lower die 3 as well. Then, a mat m cut into a predetermined size, which will be described later, is placed on the upper surfaces of the character / pattern forming lower support board 4 and the peripheral forming lower die 3.
The lower forming board W1 is connected to a hydraulic cylinder (not shown) via a rod 5 so that the upper surface of the base 6 can be slid horizontally and can be arranged and fixed directly below the upper forming board W2 by sliding. It has become.

The upper forming board W2 is the lower forming board W.
It is formed to have the same size as that of No. 1 and moves up and down via a rod 7 of a hydraulic cylinder (not shown). An upper mold fixing plate 9 for high frequency molding is fixedly mounted on the lower surface of the high frequency processing upper plate 8. On the lower surface of the high-frequency molding upper mold fixing plate 9, a rectangular frame-shaped upper peripheral mold 10 facing the lower peripheral molding mold 3 is provided in a protruding manner. Also,
On the lower surface of the high-frequency molding upper die fixing plate 9, the character / pattern forming die fixing plate 11 is located inside the peripheral molding upper die 10.
And a desired character (in this case, the Western characters “A”, “B”, “C”, “D”) on the lower surface of the character / design molding die fixing plate 11.
A plurality of molding dies 12 formed by projecting "E") are arranged at predetermined positions.

In FIG. 2, S is a heat-meltable resin, for example, a rectangular laminated resin sheet formed of foamed vinyl chloride, and the upper surface thereof is melt-pressed at a predetermined position on the surface of the mat m. A plurality of characters / patterns a, in the figure, the Western letter "A" having the same contour as each Western letter of the mold 12
"B", "C", "D", and "E" are provided in a horizontal row with some cuts left so that they do not easily come off. It should be noted that it is preferable that the pasting resin sheet S has a color different from that of the mat m.

Reference numeral 13 denotes a plurality of characters provided on the bonding resin sheet S, which holds the bonding resin sheet S fitted therein.
A holding member for melt-pressing the design a onto a predetermined position of the mat m placed on the upper surface of the lower molding board W1. The holding member 13 is made of an insulating material and has a length that substantially traverses the mat m when placed on the upper surface of the mat m, and holding pieces 15 protruding outward are provided on both sides of a horizontally long rectangular flat plate frame body 14. Has been. Further, a plurality of shift preventing projections 16 are integrally provided at appropriate positions on the lower surface of the flat plate frame body 14.

Further, numeral 17 is a fixing jig which is arranged along the outer peripheral edge of the mat m so as to cover the upper surface of the character / pattern forming lower support board 4 and to arrange the holding member 13 at a predetermined position. . The fixing jig 17 is formed in a side surface L shape from a horizontal plate portion 17a and a vertical plate portion 17b.
7a is provided with a concave fitting portion 18 into which the holding piece 15 is fitted without rattling, and on both sides of the lower end surface of the vertical plate portion 17b,
A fixing pin 20 which is detachably fitted into a pair of pin holes 19 formed on the upper surface of the high-frequency molding lower mold fixing plate 2 outside the peripheral molding lower mold 3 is provided in a protruding manner. In the mat m according to the present invention, for example, a filament group formed by melting a synthetic resin of soft vinyl chloride and spun is deposited to a predetermined thickness to form a loop layer, and a synthetic resin sheet is also attached to the lower surface thereof. Is manufactured and cut into a rectangular shape that is slightly larger than the lower die 3 for peripheral molding. The material is not limited to the above-mentioned soft vinyl chloride, but other soft synthetic resin may be used without forming the loop layer.

Next, a method of manufacturing a mat with characters / designs using the above manufacturing apparatus will be described. First, as shown in FIG. 3, a mat m cut into a rectangular shape of a predetermined size is placed at a predetermined position on the upper surface of the character / pattern forming lower support board 4, and the lower peripheral edge portion of the mat m is peripherally formed. It is supported on the upper surface of the lower mold 3. Then, as shown in FIG. 4, the horizontal plate portions 17a are directed inward toward each other so as to be positioned on the upper surface of the mat m, and the fixing pins 20 are fitted into the respective pin holes 19 to arrange the both fixing jigs 17. Next, as shown in FIG. 5, the holding pieces 13 on both sides are fitted into the concave fitting portions 18 of the respective fixing jigs 17, whereby the holding members 13 are arranged at predetermined positions on the upper surface of the mat m. Further, as shown in FIG. 6, the bonding resin sheet S is fitted into the space E of the flat plate frame 14. In this state,
As shown in FIG. 7, the fixing jigs 17 on both sides are removed. At this time, the respective shift-preventing projections 16 on the lower surface of the flat plate frame 14 bite into the loop layer of the mat m, so that the displacement of the holding member 13 can be prevented.

The lower molding board W1 on which the mat m is set in this way is slid by a hydraulic cylinder to be arranged and fixed directly below the upper molding board W2. At this position, each letter a of the bonded resin sheet S and the letter of each molding die 12 match in the vertical direction. Then, as shown in FIG. 8, the upper molding board W2 is lowered to move the upper molding board W2 and the lower molding board W2.
1 and 2 are subjected to high-frequency heating in a state of being combined with each other, and each molding die 12 separates the letter a that is easily separated from the bonding resin sheet S by pressing and separates it, and melts in a buried state on the surface of the mat m. Crimp. At the same time, a frame-shaped flat portion n is molded along the outer peripheral edge of the mat m by the upper surface of the peripheral molding lower mold 3 and the peripheral molding upper mold 10. By this, unnecessary portions on the outside are melted and removed.

Next, the upper molding board W2 is pulled up, the holding member 13 is removed, and the unnecessary bonding resin sheet S is also removed, whereby the character / patterned mat M shown in FIG. 9 is obtained. The holding member 13 is not limited to the shape, and various shapes can be changed depending on the arrangement position of the character / pattern a.

[0015]

As described above, the characters according to the present invention
The method and apparatus for manufacturing a mat with patterns are such that characters and
The heat-fusible laminating resin sheet S provided so that the pattern a can be separated is positioned and arranged by the holding member 13, and the upper molding board W is formed.
2 is lowered and the letters / patterns a of the above-mentioned bonded resin sheet S are melt-pressed to the surface of the mat m by high-frequency press working. The complicated process of repeating high frequency press machining twice before and after the process is not required, and the production efficiency is improved, which in turn reduces the manufacturing cost. It has the advantage that

[Brief description of drawings]

FIG. 1 is a schematic sectional view of an apparatus for producing a mat with characters / designs according to the present invention.

FIG. 2 is a perspective view of a bonded resin sheet, a holding member, and a fixing jig.

FIG. 3 is a schematic cross-sectional view of a manufacturing apparatus showing a procedure for manufacturing a mat with characters / designs.

FIG. 4 is a schematic plan view of the same.

FIG. 5 is a schematic plan view of the same.

FIG. 6 is a schematic plan view of the same.

FIG. 7 is a schematic plan view of the same.

FIG. 8 is a schematic plan view of the same.

FIG. 9 is a perspective view of a mat with characters / designs.

FIG. 10 is an explanatory view showing a conventional manufacturing process.

[Explanation of symbols]

W1 lower molding machine W2 upper molding machine 12 Mold 13 Holding member 17 Fixing jig a letter / pattern m mat Matte with M letter and pattern S-bonded resin sheet

Claims (2)

(57) [Claims] 1. A mat is placed on the upper surface of a lower molding board, and a heat-meltable pasting resin sheet, which is provided at a predetermined position on the upper surface of the mat so that characters and patterns can be separated, is positioned and arranged by a holding member, Next, the upper molding board is lowered, and the characters and patterns of the above-mentioned laminated resin sheet are melt-pressed onto the surface of the mat by high-frequency pressing.
Manufacturing method of mat with pattern. 2. A lower molding plate on which a mat is placed, and an upper molding plate provided with a mold for freely contacting and separating from the lower molding plate and for high-frequency press working. Is a fixing jig arranged so that it can be freely attached and detached along the outer peripheral edge of the placed mat, and a heating and melting property which is engaged with the fixing jig so that characters and patterns can be separated. And a holding member for holding the laminated resin sheet of 1 above and arranging the same at a predetermined position on the upper surface of the mat, and a manufacturing apparatus for a mat with characters / patterns.