JP2006513802A - Non-slip sheet manufacturing equipment for mats and manufactured sheets - Google Patents

Abstract

The present invention relates to a mat anti-slip sheet manufacturing apparatus and an anti-slip sheet manufactured by the apparatus. The manufacturing apparatus is mounted on the frame in a rotatable manner so as to be in contact with one surface of the sheet, and is rotatable on the frame so as to be spaced apart from the base roller at a predetermined interval. Between the forming member and the base roller, and a forming roller with a recess having a non-slip subpattern formed on the surface of the sheet to compress the other side of the sheet. Main / secondary so that the surface portion of the sheet is in contact with at least the outer periphery of the forming roller within a predetermined length of the defined nip and is in contact with the surface of the forming roller through the through hole. And a molding member having a plurality of through holes of the anti-slip pattern. Each sub-pattern has several small protrusions and a continuous cross-shaped or X-shaped cross section, and protrudes from at least a surface portion of each protrusion of the main pattern.

Description

  The present invention relates to a mat anti-slip sheet manufacturing apparatus and an anti-slip sheet manufactured by the apparatus. In particular, the anti-slip sheet of the present invention has a double anti-slip pattern in its molding region.

  In general, mats are laid on the interior floors of vehicles, houses, ships, airplanes or trains, and in particular the floors of building entrances or hallways (hereinafter referred to as “floors”) on which the underlying nonwoven or carpet material is applied. ”). The mat may be made of a single material, but here it is mainly in contact with the floor underneath the cushion sheet, with the cushion sheet, such as the upper base nonwoven fabric and carpet, generally exposed to the outside Base sheet to be used. Protrusions having a specific shape for preventing the mat from sliding on the floor are formed in the base sheet region that contacts the floor. However, in conventional apparatus and methods for forming protrusions, the ends of the protrusions are rounded without being sharply angled, so the protrusions do not have an excellent frictional force against the underlying nonwoven fabric, which is the desired result. Not shown. With regard to improving the mat's anti-slip properties, several studies have been carried out, especially on vehicle mats, but no satisfactory results have been obtained so far.

  As a technique for solving the above-mentioned problems, Korean published patent publication 2001 No. 1057996 entitled “Matte having protrusions on the bottom and manufacturing method and apparatus thereof” has been published. However, this apparatus and method produce a sheet at a very low speed by using a so-called rotocure apparatus, that is, a heat drum, the mat product is produced only about 1.5 km per day, and the mat product has a first protrusion. Only patterns are molded. As a result, there is a problem that mat products do not possess excellent anti-slip properties.

  Therefore, the present invention has been made in view of the above-mentioned problems, and the object of the present invention is to enhance the non-slip characteristics of the mat against the interior of the vehicle, the entrance of the building or the floor of the building corridor, and increase the daily output. To provide an apparatus for manufacturing an anti-slip sheet for mats having improved sharpness at the ends of the protrusions and a sub-pattern of protrusions at the ends of the protrusions in order to increase the apparatus by about 4 to 5 times. .

  Another object of the present invention is to improve the anti-slip characteristics and increase the price competitiveness by increasing the average daily production to about 6 to 8 km. An object of the present invention is to provide a mat anti-slip sheet having a protrusion sub-pattern at the portion.

  Further objects and advantages of the present invention can be more fully understood from the following detailed description taken in conjunction with the accompanying drawings.

  According to an aspect of the present invention, there is provided an apparatus for manufacturing an anti-slip sheet for mats, and a mixing unit for measuring and mixing raw materials such as elastic amorphous resin having viscosity and rollability with respect to a roll 10 and examples of the raw material include styrene / butadiene / styrene (SBS), thermoplastic olefin (TPO), thermoplastic elastomer (TPE), polyvinyl chloride (PVC), etc. A kneading unit 20 having a pair of rollers for kneading the raw material, a roller for rolling the molten raw material, and a predetermined thickness and width of the raw material from the kneading unit 20 A calender unit 30 having a plurality of rollers for forming a sheet on the sheet, and a raster line is brought into contact with one side of the sheet at the calender line. Includes a base roller that is rotatably mounted on the frame in order to apply a predetermined pattern to the sheet surface, and an embossing unit 40 that includes a forming roller having a recess formed thereon. A rotating shaft rotatably mounted on the frame so as to be spaced from the base roller at a predetermined interval, and a surface of the forming roller for contacting the other side of the sheet. Re-cooling the stacked sheets via the embossing unit 40, including a cylindrical roller having a molded anti-slip sub-pattern and a cooling water pipe disposed in the cylindrical roller to supply cooling water to the cylindrical roller A cooling unit 50, a winding unit 60 for winding the laminated sheets around a winding roller, a molding member and a base Arranged to contact at least the outer periphery of the forming roller within a predetermined length of the nip defined with the roller, and the surface portion of the sheet passes through the through hole and contacts the surface of the forming roller. A molding member having a plurality of through-holes in a primary / secondary anti-slip pattern so that the surface portion of the sheet has an average width greater than that of the through-holes while passing through the ends of the through-holes. An anti-slip sheet for mats in which a plurality of main protrusions are formed, and small protrusions are formed on each surface of the main protrusions by an anti-slip subpattern supplied in the shape of a recess (depression) on the surface of the forming roller A manufacturing apparatus is provided.

  In the non-slip sheet manufacturing apparatus according to the preferred embodiment of the present invention, the sheet includes a moldable base sheet made of an amorphous resin having roll viscosity and elasticity, and the base sheet is a calendar. The sheet is processed to a predetermined temperature by a mixing unit, kneading unit and calendar unit in the line, and the sheet is fed towards the nip via a feed roller mounted on the frame separated from the calendar line; Includes a cushion seat laminated on the base seat.

  In the non-slip sheet manufacturing apparatus according to the preferred embodiment of the present invention, the anti-slip subpattern is formed on the surface of the forming roller in a continuous cross or X shape along the longitudinal direction of the forming roller. The non-slip main pattern includes a plurality of holes spaced from each other at a predetermined interval and having a cross-shaped or diamond-like cross section.

  In the apparatus for manufacturing an anti-slip sheet for mats according to the preferred embodiment of the present invention, the forming member surrounds the outer periphery of the forming roller and holds a slight gap from the outer periphery of the forming roller having a recess (depression). Thus arranged so that it can rotate with the forming roller.

  According to another aspect of the present invention, a moldable base sheet, a thermoplastic cushion sheet laminated on one side of the base sheet and made of a fabric such as carpet or nonwoven fabric, and the base sheet Formed by sequential mixing, kneading, calendering, cooling and winding of an elastic amorphous resin with viscosity and rollability to the roll, with some main protrusions formed on the other side of the sheet Examples of the raw material include styrene / butadiene / styrene (SBS), thermoplastic olefin (TPO), thermoplastic elastomer (TPE), polyvinyl chloride (PVC), and the like. Each of them has a substantially uniform width having a cross-shaped section or a diamond-shaped section protruding from the bottom surface of the base sheet by a predetermined length. And a plurality of small protrusions each having a continuous cross-shaped cross section or X-shaped cross section, or each protrusion of the main pattern including an enlarged portion having a width greater than the average width of the uniform portion An anti-slip sheet for a mat having a sub-pattern protruding from at least one surface portion of the mat is provided.

  Hereinafter, an anti-slip sheet manufacturing apparatus for mats according to a preferred embodiment of the present invention will be described in detail with reference to the accompanying drawings.

  FIG. 1 is a conceptual view schematically showing an apparatus for manufacturing a mat anti-slip sheet according to a preferred embodiment of the present invention.

  As shown in FIG. 1, the apparatus for manufacturing a non-slip sheet for a mat according to a preferred embodiment of the present invention is laid on a floor inside a vehicle, a house, a ship, an airplane, or a train. The object is to minimize the amount of sliding of a mat placed on the floor of a building entrance or hallway (hereinafter referred to as “floor”) on which a nonwoven fabric or carpet material is stuck.

  The manufacturing apparatus 100 includes an embossing unit 40 modified from a typical embossing unit of a calendar line, a preceding process unit including a mixing unit 10, a kneading unit 20 and a calendar unit 30, a cooling unit 50 and a hoisting unit. A subsequent process unit including the unit 60.

  The mixing unit 10 includes a measuring instrument 12 for measuring a raw material such as an elastic amorphous resin having viscosity and rollability with respect to a roll. Examples of the raw material include styrene / butadiene / styrene (SBS), thermoplasticity. May contain olefins (TPO), thermoplastic elastomers (TPE), polyvinyl chloride (PVC), etc., and the mixing unit 10 mixes the raw materials with any additional raw materials and reserves the mixed raw materials. Including a mixer 14 for kneading or primary kneading.

  The kneading unit 20 uniformly mixes the molten raw material with an extruder 22 that functions to remove all foreign substances from the mixed material while melting the mixed raw material, a roller 24 for secondarily kneading the raw material. And a pair of rollers 26 for rolling into a.

  The mixing 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, i.e., determining the stretch characteristics of the final product.

  The embossing unit 40 generally functions to provide a raster or gloss pattern on the surface of the sheet at the calendar line. However, according to the present invention, the embossing unit 40 is modified to form a non-slip pattern on the surface of the sheet (especially the base sheet). The embossing unit 40 will be described in detail later.

  The cooling unit 50 functions to cool the gelled product and thereby solidify the product. In the cooling unit 50, the laminated mat sheets are cooled while passing through a roller 52 to which cooling water is supplied.

  The winding unit 60 functions to wind the completed mat sheet around the winding roller 62.

  FIG. 2 is an enlarged sectional view of an important part (that is, an embossing unit) according to a preferred embodiment of the apparatus for manufacturing a non-slip sheet for mat shown in FIG.

  As shown in FIG. 2, the embossing unit includes a base roller 120 that is rotatably mounted on the frame 101 (see FIG. 4) so as to contact one side of the raw material sheet 112 supplied from the sheet supply unit 110. A forming roller 130 rotatably mounted on the frame 101 so as to be spaced from the base roller 120 at a predetermined interval and having a recess on its surface, and a nip N together with the base roller 120 And a forming member 140 disposed on the outer periphery of the forming roller 130 so as to define (see FIG. 4).

  The sheet supply unit 110 functions to continuously supply the sheet 112, and the sheet 112 is heated to a predetermined temperature while moving toward the nip N. Although the sheet 112 can be manufactured from a single moldable material, the sheet 112 in this embodiment is a base supplied from a calendar unit 30 in which the base sheet 114 is preprocessed in a formable manner. It is divided into a seat 114 and a cushion seat 116 laminated on the base seat 114. The base sheet 114 is rolled through the calendar unit 30 under a predetermined temperature condition so as to obtain a predetermined stretch ratio, and the cushion sheet 116 is cushioned by the cushion roller 118. Non-woven fabric or carpet stock made in advance so that it can be unwound.

  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 the assembly of the forming roller and the forming member shown in FIG.

  As shown in FIGS. 2 to 4, the forming roller 130 with a recess (recessed portion) includes a rotating shaft 132 mounted on the frame 101, and a slip mounted integrally on the rotating shaft 132 and formed on the surface thereof. A hollow cylindrical roller 131 having a hollow structure having a stop sub-pattern 134 and an open end 136 and a closed end 138, and a cooling water pipe 133 disposed in the cylindrical roller 131 for supplying cooling water into the cylindrical roller 131, including. The cooling water supplied through the cooling water pipe 133 is discharged through the open end 136 and is discharged after being received by a discharge bucket (not shown). Or the cooling water pipe 133 may be arrange | positioned in the rotating shaft 132 provided with the cooling water discharge port.

  The anti-slip sub-pattern 134 is accomplished in a cross or X shape that continues along the length of the forming roller 130 as shown in FIGS. 5A and 5B. The surface of the forming roller 130 in FIG. 3 is an example of a cross-shaped anti-slip pattern in FIG. 5A.

  Referring again to FIGS. 2-4, the molded member 140 is cylindrical with a predetermined thickness. The forming member 140 has a plurality of through holes 142 for allowing at least a part of the base sheet 114 to pass therethrough. The forming member 140 is arranged so as to hold a slight gap G (see FIG. 4) from the outer periphery of the forming roller 130 having a through hole, surround the outer periphery of the forming roller 130, and rotate with the rotation of the forming roller 130. . The forming roller 130 is equipped with a recess or groove, and both the recess and the gap G allow the flow of ambient air as the base sheet 114 passes through the through hole 142 of the forming member 140. It acts as a space for guiding and discharging to the outside. The forming member 140 can be fixed at both ends to the forming roller 130 via special welding, pressing to the forming roller 130, or a clamping member (not shown).

  As shown in FIGS. 6A and 6B, the anti-slip pattern 144 is composed of a plurality of through holes having cross-shaped or diamond-shaped cross sections that are spaced apart from each other at a predetermined interval. 3 and 4 show a through hole with a diamond-shaped cross section.

  2 to 4, in the nip N, the surface portion of the base sheet 114 has several main protrusions wider than the average width of the through holes 142 while passing through both ends of the through holes 142 of the anti-slip main pattern 144. 152 is formed, and the anti-slip sub-pattern 134 forms a small protrusion 154 on the surface of the main protrusion 152.

  Hereinafter, the operation of the apparatus for manufacturing a mat anti-slip sheet according to a preferred embodiment of the present invention will be described.

  First, as shown in FIG. 1, the base sheet 114 is molded to a predetermined thickness and width while passing through the mixing unit 10, the kneading unit 20, and the calendar unit 30, and is determined in advance. After being heated to temperature, it 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 supplied toward the nip N of the embossing unit 40.

  The base sheet 114 and the cushion sheet 116 supplied to the nip N are laminated on each other by a force acting between the rotating forming member 140 and the base roller 120 to form a laminated sheet. Meanwhile, the portion of the base sheet 114 that is not laminated on the cushion sheet 116 passes through the through hole 142 of the anti-slip pattern 144. After passing through the through-hole 142, a recess (recess) formed on the outer periphery of the forming roller 130 and the forming member 140 and a slight gap G held between the outer periphery of the forming roller 130 and the forming member 140 are interposed. As the air flows out, the portion of the base sheet 114 is stretched along the direction of air flow. Next, the stretched portion of the base sheet 114 is formed as a main protrusion 152 having an average width greater than the average width of the through holes 142.

  After passing through the through-hole 142 of the forming member 140, the portion of the base sheet 114 is subsequently introduced into a recess in the anti-slip subpattern 134 formed on the surface of the forming roller 130, thereby A small protrusion 154 is formed on the surface of the main protrusion 152. Since the forming roller 130 is cooled by the cooling water supplied to the inside of the forming roller 130 through the cooling water pipe 133, the base sheet 114 provided with the main protrusion 152 and the small protrusion 154 is rotating. It leaves | separates from the nip N, without adhering to the forming roller 130 and the forming member 140. The stacked sheets 150 are conveyed toward the cooling unit 50. The sheets 150 stacked via the embossing unit 40 are cooled again by the cooling unit 50, and the anti-slip pattern formed on the surface of the sheet 150 is further cured. Next, the laminated sheet 150 is finally wound around the winding roller 62.

  7A and 7B are plan views showing an example of a non-slip pattern on the surface of the final sheet product manufactured by the mat sheet manufacturing apparatus, that is, the base sheet surface, and FIG. 8 is an enlarged view of FIG. 7A. It is.

  As shown in FIGS. 7A to 8, the mat non-slip sheet 150 manufactured by the mat sheet manufacturing apparatus according to the preferred embodiment of the present invention has a main protrusion 152 protruding vertically from one surface of the base sheet 114. And a sub pattern 158 having a small protrusion 154 protruding perpendicularly from the surface of the protrusion 152 of the main pattern 156.

Each of the main projection 152 is a cross-sectional diamond shape, a bottom advance a uniform portion 152a protruding in the width W ₁ of substantially uniform up to a length that is determined, uniform portion at the tip of the uniform portion 152a from the base sheet 114 and a larger portion 152b which is formed in a wide width _{W 2} than the average width _{W 1} of 152a.

  The sub-pattern 158 includes small protrusions 154, and each of the small protrusions 154 has a continuous cross-shaped structure (see FIG. 7A) or a continuous X-shaped structure (see FIG. 7B).

  Therefore, when the mat formed by cutting the non-slip sheet 150 in FIG. 8 is placed on the bottom made of non-woven fabric, the extended portion 152b of the main protrusion 152 and the small protrusion 154 of the sub pattern 158 become mats. Maximize interference with the nonwoven, thereby minimizing mat slip from the nonwoven.

  Although the present invention has been described in relation to an apparatus for manufacturing a mat anti-slip sheet according to a particular exemplary embodiment of the present invention that employs calendar technology, the apparatus for manufacturing an anti-slip sheet for mat has been described in the foregoing embodiment. It is not limited. For example, the present invention can be changed to a forming roller in a T-die line or a rot-cure line.

  In addition, the mat anti-slip sheet manufacturing apparatus of the present invention has a low operating speed, which can be applied to a press apparatus for manufacturing an expensive mat.

  As described above, the apparatus for manufacturing a non-slip sheet for mats according to the present invention forms a non-slip subpattern on the surface of the molding roller and a main pattern on the cylindrical roller, or contacts the molding roller. The mat sheet is manufactured by forming the belt, and the productivity exceeds the conventional calendar line. That is, the mat anti-slip sheet manufacturing apparatus can have an improved daily production of about 6 to 8 km per day. It should be understood that productivity is improved by about 4 to 5 times that of the prior art. Furthermore, the present invention can secure various anti-slip patterns based on the anti-slip sub-pattern of the forming roller and the anti-slip main pattern of the forming member for improving the anti-slip characteristics of the final sheet product.

1 is a conceptual diagram schematically showing an apparatus for manufacturing a mat anti-slip sheet according to a preferred embodiment of the present invention. It is an expanded sectional view of the important part by suitable embodiment of the anti-slip sheet manufacturing apparatus for mat | matte shown in FIG. FIG. 3 is an exploded perspective view of a forming roller and a forming member shown in FIG. 2. FIG. 3 is a longitudinal sectional view of the assembly of the forming roller and the forming member shown in FIG. 2. It is a conceptual diagram which shows the anti-slip | slipping subpattern of the shaping | molding roller shown in FIG. It is a conceptual diagram which shows the non-slip | skid main pattern of the shaping | molding roller shown in FIG. It is a top view of the example of the non-slip pattern in the surface of the sheet | seat for mats manufactured by the sheet manufacturing apparatus for mats by suitable embodiment of this invention. Fig. 7a is an enlarged view of Fig. 7a.

Claims (4)

An apparatus for manufacturing a non-slip sheet for mats,
A mixing unit (10) for measuring and mixing raw materials such as elastic amorphous resin having viscosity and rollability with respect to the roll is provided. Examples of the raw materials include styrene / butadiene / styrene (SBS), heat Including plastic olefin (TPO), thermoplastic elastomer (TPE), polyvinyl chloride (PVC), etc.,
A kneading unit (20) having an extruder for removing foreign substances from the raw material and melting the raw material, a roller pair for kneading the raw material, and a roller for rolling the molten raw material,
A calendar unit (30) having a plurality of rollers for forming the raw material from the kneading unit (20) into a sheet having a predetermined thickness and width;
A base roller that is rotatably mounted on a frame for forming a raster (glossy) or predetermined pattern on the surface of the sheet in contact with one side of the sheet in a calendar line and molded thereon And an embossing unit (40) including a forming roller having a recess, the forming roller being rotatable on the frame so as to be spaced from the base roller at a predetermined interval. A rotating shaft to be mounted, a cylindrical roller having a non-slip sub-pattern formed on its surface for contacting the other side of the sheet, and in the cylindrical roller for supplying cooling water to the cylindrical roller A cooling water pipe disposed on the
A cooling unit (50) for re-cooling the sheets stacked via the embossing unit (40);
A winding unit (60) for winding the laminated sheet around a winding roller;
It is arranged to contact at least the outer periphery of the forming roller within a predetermined length of the nip defined between the forming member and the base roller, and the surface portion of the sheet passes through the through hole. And a molding member having a main / sub anti-slip pattern of a plurality of through-holes so as to contact the surface of the molding roller,
Accordingly, the surface portion of the sheet forms a plurality of main protrusions having an average width larger than that of the through hole while passing through the end of the through hole, and the forming is performed on the surface of each of the main protrusions. An apparatus in which small protrusions are formed by the anti-slip subpattern provided in the shape of a recess (depression) on the surface of the roller. The above sheet
A base sheet made of an amorphous resin having roll viscosity and elasticity is included, and the base sheet reaches a temperature predetermined by the mixing unit, the kneading unit, and the calendar unit in the calendar line. Processed,
The apparatus of claim 1, further comprising a cushion sheet fed toward the nip via a feed roller mounted separately from the calendar line onto the frame and laminated onto the base sheet.   The anti-slip sub-pattern is continuously formed in a cross or X shape along the longitudinal direction of the forming roller on the surface of the forming roller, and the anti-slip main patterns are spaced apart from each other at a predetermined interval; The apparatus of claim 1 including a plurality of holes having a cross-shaped or diamond-like cross section. An anti-slip sheet for mats,
A moldable base sheet;
A thermoplastic cushion sheet laminated on one side of the base sheet and made of a fabric such as carpet or nonwoven fabric;
Sequential mixing, kneading, calendering, cooling and winding of an elastic amorphous resin having viscosity and rollability with respect to the roll, having several main projections formed on the other side of the base sheet Examples of the raw material include styrene / butadiene / styrene (SBS), thermoplastic olefin (TPO), thermoplastic elastomer (TPE), polyvinyl chloride (PVC), and the like, Each of the main protrusions has a substantially uniform uniform portion having a cross-shaped cross section or a diamond-like cross section protruding from the bottom surface of the base sheet by a predetermined length, and a width larger than the average width of the uniform portion. Including an enlarged portion having
A non-slip sheet for mats, comprising a number of small protrusions each having a continuous cross-shaped cross section or X-shaped cross section, or a sub-pattern protruding from at least one surface portion of each protrusion of the main pattern.

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