JPH05311561A - Production of mat comprising filament loop aggregate - Google Patents

Abstract

PURPOSE:To provide a method for producing the mat comprising a thermoplastic synthetic resin filament loop aggregate containing easily formed filament loops, the filaments being strongly fused to each other, and having durable properties including tensile strength. CONSTITUTION:The production method comprises lowering plural filaments 2 extruded from a die 1 between a rotating net conveyor 3 and a cooling roll 4, bringing the outside filament 2a into contact with the conveyor 3 and also bringing the other outside filament 2b into contact with the cooling roll 4 to curve, cool and harden the filaments, respectively, interlockingly curving the inside filaments 2c into the loop-like shape to form a filament loop aggregate 7, and subsequently lowering the formed filament loop aggregate 7 in the substantially vertical direction.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a mat composed of a filament loop aggregate, and more particularly to a three-dimensional net mat made of a thermoplastic synthetic resin filament loop aggregate used as a rug for door mats, floor mats and the like. The manufacturing method of

[0002]

2. Description of the Related Art Conventionally, in this type of mat manufacturing method,
For example, U.S. Pat. Nos. 3,837,988 and 4,
No. 351683 and British Patent No. 1269108, a characteristic feature is that a cooling liquid is used as a direct medium when bending a filament extruded from a die into a loop shape, and thus a loop is formed. There was a problem in the durability of the product because the filaments were not sufficiently welded to each other and lacked particularly in tensile strength.

[0003]

SUMMARY OF THE INVENTION A first object of the present invention is to form a loop of filaments easily, and to firmly weld filaments to each other, and to provide a durable thermoplastic resin including tensile strength. The present invention provides a method for producing a mat made of a synthetic resin filament loop assembly. A second object of the present invention is to provide a simple method for producing a mat composed of a filament loop assembly made of thermoplastic synthetic resin.

[0004]

[Means for Solving Problems]

In order to achieve this object, the method for producing a mat composed of the filament loop assembly 7 according to the present invention comprises a plurality of filaments 2 of thermoplastic synthetic resin in a molten state extruded from a die 1, It descends between the net conveyor 3 and the cooling roll 4, which rotate slower than the descending speed, and one outer filament 2a is brought into contact with the net conveyor 3 and the other outer filament 2b is brought into contact with the cooling roll 4, and curved in a loop shape. Then, the contact portion is cooled and hardened, and the inner filament 2c is bent in a loop shape in association with the bending and cooling hardening of both outer filaments 2a and 2b due to this contact to form the filament loop aggregate 7 and The filament loop assembly 7 is lowered in a substantially vertical direction at a speed lower than the descending speed of 2. Than it is.

[0006]

Function: Extruded from die 1 180 degrees Celsius to 2 degrees Celsius
The filament 2 of 00 degrees is exposed to the atmosphere and its temperature is rapidly lowered, but by heating the filament 2 which is descending by the heating means and adjusting the temperature of the filament 2,
The diameter of the formed filament loop is regulated. That is, when the filament 2 is heated to a high temperature, a small diameter loop is formed, whereas when the temperature of the filament 2 is low, a large diameter loop is formed. Therefore, the size of the loop is regulated by the degree of heating of the filament 2 and the loop assembly is formed. The filament density and porosity of the body 7 can be adjusted.

The plurality of molten filaments 2 extruded from the die 1 descend between the chill roll 4 and the net conveyor 3 rotating at a slower speed than the descending speed of the filament 2, and the outer filament 2a of the one filament 2a is transferred to the net conveyor. 3 and the other outer filament 2
b is brought into contact with the cooling roll 4. By this contact, both outer filaments 2a, 2b are curved so as to form a loop, and the contact portions thereof are hardened by cooling, and the inner filaments are interlocked with the bending and cooling hardening of both outer filaments 2a, 2b. 2c is curved so as to form a loop. Except for the contact portion between the net conveyor 3 and the cooling roll 4, the filaments 2 in a molten state are likely to form a loop, and are easily welded at their contact points, and the welds at the contact points are strong.

In order to cool and harden the filament 2 that contacts the net conveyor 3 and the cooling roll 4, it is necessary to keep the net conveyor 3 and the cooling roll 4 at a low temperature.
The outer filaments 2a and 2b, which come into contact with the net conveyor 3 and the cooling roll 4, respectively, are rapidly cooled and hardened at their contact portions, and therefore the surface 8 of the filament loop assembly 7
Thus, the back surface 12 becomes stable, and thus the three-dimensional filament loop assembly 7 can be formed.

When the loop is formed between the net conveyor 3 and the cooling roll 4, the filament loop is swung by the air flow 9 to give the loop being formed an irregular curve and to increase the contact points between filaments. That is, when the airflow 9 is applied to the filament 2 that is descending from the die 1, the filaments contact and weld to each other before the loop is formed, and the desired loop formation is hindered. Therefore, the airflow is applied to the filament loop during the loop formation. The filaments are oscillated, which makes the loop curvature irregular or increases the points of contact between filaments.

The filament loop assembly 7 thus formed is taken up by the net conveyor 3 at a speed slower than the descending speed of the filament 2 toward a substantially vertical downward direction, and the filament loop assembly 7 being descended is cooled. As a cooling means, a cooling airflow 11 is applied from the surface 8 or a cooling liquid is sprayed to cool the filament loop assembly. However, since the filament loop assembly 7 has many small voids between the loops, the cooling is efficient. It can be done.

[0011]

Embodiments of the present invention will be described below with reference to the accompanying drawings. FIG. 1 is a side view showing a main part of an apparatus for carrying out a manufacturing method according to the present invention, in which a thermoplastic resin is extruded from a die 1 and a plurality of filaments 2 aligned vertically and horizontally at intervals are continuously formed. Forming these filaments 2
Is vertically lowered toward the space between the net conveyor 3 and the cooling roll 4 which are arranged to face each other in the horizontal direction.

The distance from the die 1 to the upper end of the net conveyor 3 and the upper end of the cooling roll 4 is set to 3 cm to 10 cm. Normally, the filament 2 extruded from the die at 180 to 200 degrees Celsius is exposed to the atmosphere and is rapidly exposed. Although the temperature is lowered, heating means 6 such as a ceramic far-infrared heater provided with heat reflecting plates 5 on both sides of the filament 2 is arranged in the descending region of the filament 2, and the heating means 6 heats the heating means 6. The filament 2 is not cooled.

This heating regulates the temperature of the descending filament 2 and regulates the filament loop formation conditions. Even filaments of the same diameter form smaller loops as filaments with a higher temperature. Is heated to a high temperature of 180 to 200 degrees Celsius, which is almost the same as the extrusion temperature, and a small diameter loop (for example, 6 mm to 7
mm) is formed. On the other hand, the heating degree can be reduced to form a large-diameter loop (for example, about 10 mm to 12 mm), and in some cases, a larger-diameter loop can be formed without heating the filament.

A driving roll 30 and a driven roll 31 which rotate in the direction of the arrow are arranged so as to face each other in the vertical direction (vertical direction), and the driving roll 30 of the net conveyor 3 and the cooling roll 4 face each other in a substantially horizontal direction. The net conveyor 3 is rotated in the vertical direction, and the cooling roll 4 is rotated in the direction of the arrow at a speed slower than the descending speed of the filaments.

Of the filaments 2 in a molten state that fall between the net conveyor 3 and the cooling roll 4, one outer filament 2a is brought into contact with the net conveyor 3 and the other outer filament 2b is surrounded by the peripheral surface of the cooling roll 4. Contact the outer filaments 2 by this contact.
Each of a and 2b is curved in a loop shape.

As shown in FIG. 4, the metal wire 16
As shown in FIG. 5, the surface of the net conveyor 3 having a net-like structure is formed with appropriate irregularities, and the irregularities contact the net conveyor 3 to form the outer filament 2
It easily catches a and promotes loop formation. Although the temperature of the conveyor net once rises due to the contact of the high temperature filament, it is cooled mainly by air while circulating between the drive roll 30 and the driven roll 31, and becomes low when the filament 2 is contacted again. It is desirable that the surface temperature of the net conveyor 3 is maintained at a low temperature of 50 degrees Celsius or less, so that the contact portion of the outer filament 2a that contacts the net conveyor 3 is cooled and hardened.

The structure of the net constituting the net conveyor is not limited to those shown in FIGS. 4 and 5, and various structures can be adopted.

The cooling roll 4 is formed in a pipe shape,
Various cooling media other than the cooling water 20 can be used, and the type and cooling temperature are selected to adjust the peripheral surface temperature of the cooling roll 4. The cooling water 20 inside can be circulated to enhance the cooling effect. The temperature of the peripheral surface of the cooling roll 4 is preferably maintained at a low temperature of 30 degrees Celsius or less. The outer filament 2b in contact with the cooling roll 4 is curved so as to form a loop, and the contact portion is rapidly hardened.

The outer diameter of the cooling roll 4 is preferably smaller than that of the drive roll 30 of the net conveyor, and preferably the outer diameter is within the range of 10 mm to 25 mm. When the diameter of the cooling roll 4 is small, the contact area with the filament forming the loop is large, which promotes rapid cooling and hardening of the filament.

The inner filament 2c is also curved in a loop shape in association with the bending of both outer filaments 2a, 2b due to the contact between the net conveyor 3 and the cooling roll 4 and the cooling and hardening, whereby the filament loop assembly 7 is formed. Form.

The rapid cooling of the outer filament 2b by contact with the cooling roll 4 brings about the cooling and hardening of the surface 8 of the filament loop assembly 7 immediately after being formed, and is effective in keeping the filament loop assembly 7 in a three-dimensional shape. On the other hand, except for the contact portion between the net conveyor 3 and the cooling roll 4, the filament 2 itself has a high temperature, so that it is easy to form a loop, and welding at mutual contact points is easy and strong.

Further, when the loop is formed, it is preferable that the filament 2 is swung by the air flow 9 when the loop is formed so that the filament 2 is further irregularly curved. That is, an air blower (not shown) such as a blower forms an air flow 9 that traverses the filament loop assembly 7, and when this air flow traverses the filament loop assembly 7, the filaments at the time of loop formation are oscillated. The airflow 9 is formed below the cooling roll 4 and the drive roll 30 of the net conveyor, and it is particularly desirable to flow along the lower peripheral surface of the cooling roll from the lower peripheral surface to the lower peripheral surface of the drive conveyor of the net conveyor (Fig. 1, see FIG. 2).

When the air current is directly applied to the descending filament, the predetermined loop formation is largely hindered by the contact and welding of the filaments immediately before the loop formation.
Is the cooling roll 4 and the drive roll 30 of the net conveyor
Since it is formed below, the air current does not hit the descending filament 2. In order to completely prevent the airflow from directly hitting the descending filament and to control the direction of the airflow, the partition wall 10 can be provided if necessary.

The filament loop assembly 7 thus formed abuts the back surface of the net conveyor 3 and is guided by the net conveyor 3 and the guide roll 32 below.
The filament loop assembly 7 is cooled while taking it down in a substantially vertical direction while taking it slower than the descending speed of the filament 2.

The descending filament loop assembly 7 is cooled by the cooling air flow 11. That is, as the net conveyor 3 moves downward, the net conveyor 3
The cooling airflow 11 is applied to the filament loop assembly 7 which is brought into contact with the back surface 12 and descends in a substantially vertical direction to cool the filament loop assembly 7.

The cooling airflow 11 is formed by appropriately adjusting the air flow rate, air pressure, etc. of a blower (not shown), and is cooled to a particularly low temperature by a cooling device (not shown), or is not cooled at room temperature. Air flow (eg, air). The three-dimensional shape of the filament loop assembly 7 is caused to flow from the front surface 8 of the descending filament loop assembly through the inside thereof to the back surface 12 and further from the gap 17 of the nets constituting the net conveyor 3 to the outside thereof. It is effective in efficiently cooling it while maintaining it (see FIG. 1).

In addition to air cooling for cooling, the cooling water 13 can be sprayed onto the descending filament loop assembly 7, which is the pressurized cooling water 1 in the pipe 14.
3 is strongly sprayed from the nozzle 18 onto the filament loop assembly 7 (see FIG. 2). The means for spraying the cooling water 13 can be variously constructed in addition to this, and the cooling water 13 includes not only cooled low temperature but also uncooled one.

Although the filament loop assembly 7 formed between the net conveyor 3 and the cooling roll 4 has a three-dimensional shape, the filament loop assembly 7 is not completely hardened yet. If the filament loop 19 in the upright state (see FIGS. 7 and 8) is partially laid down when it is lowered in the inclined state (see FIG. 6), there is a possibility that a “sagging phenomenon” may occur. The “sagging” of the filament loop assembly immediately leads to product failure.

As shown in FIGS. 1 and 2, when the filament loop assembly 7 is vertically lowered, the filament loop assembly 7 is unlikely to cause the settling phenomenon. Therefore, the filament loop assembly 7 is vertically lowered. Is desirable. From the viewpoint of preventing settling, the allowable tilt angle C when the filament loop assembly 7 is lowered is 9
0 degrees (as shown in FIGS. 1 and 2 in the vertical state) to 7
The angle is 0 degrees (in the case shown in FIG. 6), the inclination angle C is smaller than 70 degrees, and the more the horizontal angle, the more the settling is likely to occur.

Further, a frictional force effectively acts on the filament loop assembly 7 whose back surface 12 is in contact with the net conveyor 3 to prevent the downward movement of the filament loop assembly 7 which vertically descends. Furthermore, the filament loop assembly 7
It is possible to effectively prevent the downward movement of the filament loop assembly 7 by pushing the cooling air flow 11 having a large wind pressure or by blowing the cooling liquid 13 strongly on the net conveyor 3 with this pressure.

In order to completely prevent the filament loop assembly 7 from slipping off, a pin 15 protruding from the net conveyor 3 is provided so that the filament loop assembly 7 can be engaged with the pin 15 as the net conveyor 3 rotates. It can be locked (see FIG. 3).

The filament loop assembly 7 that has been cooled and left the net conveyor 3 is pulled by a guide roll (not shown) to form a mat, and if necessary, it can be further cooled in a cooling tank. Further, it goes without saying that the filament loop aggregate 7 can be formed with a mat after further adding various processes such as coloring coating.

FIGS. 7 and 8 are perspective views of the mat manufactured by the manufacturing method of the present invention. In the structure shown in FIG. 7, the mat back surface 12 is formed of a sideways loop formed by the contact of the outer filament 2a with the net conveyor 3, whereby the mat back surface 12 has a large filament density and is flat. Other filament loops 19
Is upright, the matt surface 8 consists of a loop formed by lightly contacting the outer filament 2b "on the side" of the chill roll 4, this filament loop having a chevron projection on the surface 8 side. Not not.

In the structure shown in FIG. 8, the back surface 12 of the mat is formed of loops lying sideways, and the filament loops 19 in the upright state are the same as those described above.
The matte surface 8 is on the cooling roll 4 and the outer filament 2b
And the mat surface 8 has a large filament density and is flat.

The following is a concrete configuration example. (Structural Example 1) Polyvinyl chloride (PVC) (P-1300) 100 parts Plasticizer DOP Dioctyl phthalate 50 parts Stabilizer Dibutyltin laurate 2 parts Cadmium stearate 0.6 parts Barium stearate 0.4 parts Deposition Coloring agent 0.1 part

The compound material having the above composition is formed into filaments by an extruder. The distance between the net conveyor and the cooling roll is set to 15 mm, the filament forming hole diameter of the T-die is 0.8 mm, the T-die hole arrangement is 4 rows vertically 4 mm gap, and the horizontal hole pitch is 5 mm. Distance between T-die, net conveyor and cooling roll 10
cm, Die temperature 185 ° C, Die pressure 90kg / cm ² , Extrusion pressure 190kg / cm ² , Ceramic far-infrared heater 2KW 4 pieces, Diameter of metal wire that composes net conveyor 1mm, Gap between metal wires 3mm Surface of net conveyor Temperature 35 degrees Celsius Peripheral surface temperature of chill roll 25 degrees Celsius Cooling of the filament assembly is performed by blowing a cooling airflow of 5 degrees Celsius.

Under the above conditions, the molding linear velocity was 2 m / min,
A 40 cm speed loop is created. The formed filament loop assembly has a loop diameter of about 7 mm and a thickness of 13.
It is 5 mm and the filament diameter is 1 mm.

(Structural Example 2) Polyvinyl chloride (PVC) (P-1300) 100 parts Plasticizer DIDP Diisodecyl phthalate 5.5 parts LK-40 Organic cadmium chelate 0.5 parts Cadmium stearate 0.7 parts Stearine Barium acid 0.3 parts Coloring agent 0.1 parts

The compound material having the above composition is formed into filaments by an extruder. The distance between the net conveyor and the cooling roll is also set to 15 mm, the filament forming hole diameter of the T-die is set to 0.8 mm, and the hole arrangement of the T-die is set to 4 rows of 5 mm gaps and a horizontal hole pitch of 5 mm gaps. Distance between T-die, net conveyor and cooling roll
5.5 cm T die temperature 190 ° C., die pressure 80 kg / cm
² , extrusion pressure 190kg / cm ² , ceramic far-infrared heater 2kW, 2 wire diameter of metal wire that composes net conveyor 1mm, small gap between metal wires 3mm surface temperature of net conveyor 30 degrees Celsius surface temperature of cooling roll The 22 degree filament loop assembly is cooled by blowing a cooling air flow of 10 degrees Celsius.

Under the above conditions, the molding linear velocity is 2.5 m / min.
Then, a loop with a speed of 50 cm can be made. The formed filament loop assembly has a loop diameter of about 10 mm and a thickness of 14 mm, and the filament diameter is 1.1 mm.

[0041]

[Effect] Since a high temperature filament is curved in the air to form a loop, the loop can be easily formed, and the filaments can be welded at a contact point, and the welding is also strong. This is an effect that cannot be achieved by the conventional manufacturing method in which cooling water is used as a medium, and it is easy to form a mesh mat having a three-dimensional structure, and is excellent in durability including tensile resistance.

In addition, a synergistic effect due to the fluctuation of the filament caused by the air flow is added to the bending of the filament caused by the contact between the net conveyor and the cooling roll, and an irregular loop can be formed.

The quench hardening of the outer filament by the chill roll effectively prevents the set of filament loops, in particular, the settling of the filament loops located on the surface.

Further, since the loop is formed in the air, the operation of the molding device, the machine, etc., the adjustment, and the manufacturing work are easy and efficient, and a simple manufacturing method of the three-dimensional net-like mat can be provided.

[Brief description of drawings]

FIG. 1 is a side view showing a main configuration part of an apparatus for carrying out a manufacturing method according to the present invention.

FIG. 2 is a side view showing a main part of another apparatus for carrying out the manufacturing method according to the present invention.

FIG. 3 is a side view showing a main part of the configuration of still another apparatus for carrying out the manufacturing method according to the present invention.

FIG. 4 is a partial plan view of a net of an apparatus for carrying out the manufacturing method according to the present invention.

FIG. 5 is a partially enlarged perspective view of a net of an apparatus for carrying out the manufacturing method according to the present invention.

FIG. 6 is a side view showing an inclined net conveyor in an apparatus for carrying out the present invention.

FIG. 7 is a perspective view of a filament loop assembly manufactured by the manufacturing method of the present invention.

FIG. 8 is a perspective view of another filament loop assembly manufactured by the manufacturing method of the present invention.

[Explanation of symbols]

 1 Die 2 Filament 2a Outer Filament 2b Outer Filament 2c Inner Filament 3 Net Conveyor 4 Cooling Roll 5 Heat Reflecting Plate 6 Heating Means 7 Filament Loop Assembly 8 Surface 9 Airflow 10 Partition Wall 11 Cooling Airflow 12 Backside 13 Cooling Water 14 Pipe 15 Pin 16 Metal wire 17 Gap 18 Nozzle 19 Filament loop 20 Cooling water 30 Drive roll 31 Driven roll 32 Roll C Allowable tilt angle

Claims (15)

[Claims] 1. A plurality of filaments 2 of thermoplastic synthetic resin in a molten state extruded from a die 1,
It descends between the net conveyor 3 and the cooling roll 4 rotating at a slower speed than the descending speed, and one outer filament 2a is brought into contact with the net conveyor 3 and the other outer filament 2b is brought into contact with the cooling roll 4, and curved in a loop shape. Then, the contact portion is cooled and hardened, and the inner filament 2c is bent in a loop shape in association with the bending and cooling hardening of both outer filaments 2a and 2b due to this contact to form the filament loop aggregate 7 and the filament. A method for producing a mat comprising a filament loop aggregate 7 characterized by lowering the filament loop aggregate 7 in a substantially vertical direction at a speed lower than the descending speed of 2. 2. The method for producing a mat made of a filament loop assembly 7 according to claim 1, wherein the filament 2 at the time of forming a loop is swung by an air flow. 3. The filament 2 at the time of forming the loop is oscillated by an air flow that traverses a filament loop assembly 7 formed below the cooling roll 4 and the drive roll 30 of the net conveyor 3. Item 3. A method for producing a mat comprising the filament loop aggregate 7 according to item 2. 4. A plurality of filaments 2 of thermoplastic synthetic resin descending between a net conveyor 3 and a cooling roll 4.
The mat is formed from the filament loop assembly 7 according to claim 1, wherein the mat is heated by a heating means. 5. The filament is 180 to 200 degrees Celsius.
4. The method for producing a mat comprising the filament loop assembly 7 according to claim 3, wherein the mat is heated once. 6. The production of a mat comprising the filament loop assembly 7 according to claim 1, wherein the distance from the die 1 to the upper end of the net conveyor 3 and the upper end of the cooling roll 4 is set to 3 cm to 10 cm. Method. 7. The cooling roll 4 has a diameter of 10 mm to 30.
The method for producing a mat comprising the filament loop assembly 7 according to claim 1, wherein the mat is set to mm. 8. The mat formed from the filament loop assembly 7 according to claim 1, wherein the surface temperature of the net conveyor 3 is maintained at 50 degrees Celsius or less by cooling with the rotational movement of the net conveyor 3. Production method. 9. The method for producing a mat made of a filament loop assembly 7 according to claim 1, wherein the peripheral surface of the cooling roll 4 is kept at 30 degrees Celsius or less. 10. The method for producing a mat comprising a filament loop assembly 7 according to claim 1, wherein cooling water is circulated inside the cooling roll 4 formed in a pipe shape. 11. The method for producing a mat composed of the filament loop aggregate 7 according to claim 1, wherein the filament loop aggregate 7 descending in a substantially vertical direction is cooled by air. 12. Cooling the filament loop assembly 7 by blowing cooling air to the filament loop assembly 7 which comes into contact with the back surface of the net conveyor 3 and descends in a substantially vertical direction as the net conveyor 3 moves downward. A method for producing a mat comprising the filament loop assembly 7 according to claim 1. 13. Along with the downward movement of the net conveyor 3, cooling water is sprayed onto the filament loop assembly 7 which comes into contact with the back surface of the net conveyor 3 and descends in a substantially vertical direction to cool the filament loop assembly 7. The filament loop assembly 7 according to claim 1, wherein
Of a mat made of. 14. A cooling wind and / or a cooling liquid is blown to a filament loop assembly 7 which comes into contact with the back surface of the net conveyor 3 and descends as the net conveyor 3 moves downward. The filament loop assembly 7 according to claim 1, wherein the filament loop assembly 7 is pressed against the conveyor 3.
Of a mat made of. 15. The method for producing a mat made of a filament loop assembly according to claim 1, wherein the filament loop assembly 7 is lowered at a tilt angle of vertical to 70 degrees.