Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
SPECIFICA~ION
Title of the Invention:
MAT CONSISTING OF ~I~AMENT ~OOP AG~KEGATIONS
AND METHOD AND APPARA~US FOR PRODUCING THE
SAME
Back~round Df the In~ention:
~ his invention relates to a coarse net-11ke
developed resilient mat made by complicatedly entangling
synthetic resin monofilament~ and more.particularly to
a mat consisting of fllament loop aggregations and
adapted to a porch mat of fixed dimensinns or a floor
mat formed an~ ~aid in a ~ong sheet and a method and
apparatus for produclng the same.
Instead of a conventional carpet mat or
~ynthetlc re~n mat, ~here i8 recently provided a
three-dimenslonal net-like mat consisting of synthetic
resin monofllaments high ln the water permeability
and quick dryability. Due to ~uch characteristics as
the resiliency and weather-proofness, such three-dimen-
sional ~et-llke mat is used in many indoor and outdoor
ie~ds, is applied particularly to such water u~ing
place as, or example; an inlet and outlet of a bath
room or a pool side and i8 appreciated because it i~
~k
~imple to wash and dry
Also, as this kind of three-dimensional mat
is open, the sand and gravels brought when it is trod
will drop down and will not remain on the surface.
As water or the like also will drop down, the surface
can be always kept dry It is thu~ convenient.
. In addltion, when such elastic sheet as a
synthetic resin sheet, foaming sheet or rubber sheet
i8 pasted to the lower ~urface of ~uch mat, the cushioning
property as of a mat will be able to be increased, the
sand and water dropping from the surface will be able
to be recelved by this sheet pasted to the lower surface
and the floor wi~ be ab~e to be prevented fr~m being
made dirty directly by the dropping sand and the like.
Descriptlon of the Prlor Art:
As dlsclosed in the gazette of a Japane~e
pa~ent publlcation No.14347t1972, ~uch three-dimensional
net-like mat is formed as a non-woven fabric wherein
many monofilaments made of a thermoplastlc synthetic
resln are lamlnated whl~e belng rubbed and bent, are
fu~ed at their contact points and are cooled to be
solidifled.
The formatlon of uprlght loops disclosed
ln the gazette~ of a Japanese patent publication No.
~t2Z2/lg80 and a Japanese patent laid opèn No.85061/1987
'~ 2 ~
is known as a web forming means of the above mentioned
filaments in such non-woven fabric,
Now, in the non--woven fabric formation by
the above described conventional means, in such rubbed
and bent web formation, the reslliency of the indivi-
dual rubbed and bent fllament:part itself i8 low, the
rubbed and bent fllaments by thi~ producing mean~
overlap on each other to fall down and, as a result,
a~ the entangled density of the filaments become~
higher, the re~iliency of the sheet will be lost.
~ hus, when the mat i8 u~ed9 the treading
touch will be obstructed and, when the mat i~ stored
or carried, it wlll be dlfficult to wind in the sheet-
like mat, much to the inconvenience.
On the other hand, when the web formation
is made loop-llke, the reslliency of the filament
itself in each loop-like part will be developed but,
in the web made of arcuate loops arranged in a sub-
stantially fixed form, the respective loops are only
fused at their lntersecting polnts and the contact
points between the ad~acent loops, are high in the in-
dependency and are therefore lo~ in the re~iliency
again~t treading and, as a result, no favaroble tread-
ing touch will be obtained.
- 3 -
Summar~ of the Inventlon:
~ herefore, the present invention has it as
an ob~ect to provide a mat wherein a fi~ament web i~
formed of positively closed loops to develop a filament
resiliency in each loop part and the degree of the
contact fusing between the respective loop~ i8 made
high to be able to develop a ~trong sheet resiliency
and a method and apparatus for producing the same.
Description of the Drawin~s:
The many advantages and features of the present
invention can be best under~tood and appreciated by
reference to the accompanylng drawings whereln~
Fig. 1 i~ a ~ide vlew of an essential part
~how~ng, a~ embodiment of the apparat~l~ of the pre~ent
invention;
Fig, 2 is an explanatory view showing a fila-
ment loop forming state by the apparatus of the present
invention;
Fig. 3 is a side view of an essentlal part
showlng another embodiment of the apparatus of the
pre~ent invention;
Fig. 4 19 a side view showing respective
examples of the mat of the present invention;
Fig. 5 is a step diagram for producing sheets
formed by using the method of the present invention; and
-- 4 --
~2 ~
~ ig. 6 i9 a side view showing another embodi-
ment of the mat of the present invention.
Detailed Description of the Invention:
In order to attain such ob~ect, according to
the present invention, a mat consists of upright dis-
arranged loop-llke oynthetlc resin filament three-
dimensional aggregations and has many spaces within
it to develop a cushioning property. A mat consisting
of loop~ of var~ OU9 size~ depending on the ob~ect of
the use can be provided.
In order to form such mat, several hot filaments
of a thermoplastic synthetic re~in are pre~ed and
extruded t~rough T-dle origice~ and are made to fall
toward a water surface.
A palr of lnclined panels are set as opposed
to each other on the water surface and a bundle of the
above mentioned filaments is lowered 90 a~ to drop
between these panels.
The falllng hot filaments are heated by such
heat sources as ceramic far infrared ray heaters so as
not to be cooled by the atmosphere and the inclined
parts above water of the abo~e mentioned panels act
to prevent the temperature drop of the filaments by the
radlatlon heat reflection.
Such hot filament~ are easy to make coiled
- 5 -
19~6
loops on the water surface. Unles~ the filament~ are
hot, the loops will become large. Further, in the
filaments of a reduced temperature, no coiled loop
will be formed but only a channeled rubbed and bent
form will be able to be made.
The height from the die mouth end to the
water surface i~ 5 to 100 cm. and the heat reduction of
the filaments is prevented by making the die mouth end
approach the water surface as much as possible.
The orifice diameter of the T-die i9 O. 3 to
1.5 mm. as an element determining the filament diameter,
retains the resillency and durability of the formed
f~laments and prevents the permanent set.
A mat sheet con~isting of filament aggrega-
tlons of respective width~ can be made by arranging the
numbers of orlfices correspondlng to the widths of 90,
120 and 150 c~, of intended mat sheets with an orifice
arrangement of a T-die of 3 to 6 longitud~mal rows at
the inservals of 3 to 5 mm. and a pitch of 3 to 5 mm.
in the lateral row.
lhat i~ to say, a hot filament bundle extruded
out of the die of cuch orifice arrangement i~ made
to fall upright toward cooling water and i~ received
by submerged rolls of a rotary peripheral speed well
slower than the falling speed to limit the falling speed
-- 6 --
~ 6
in water and to glve the filaments a re~istance toward
the water surface from the above mentioned roll~.
Loops hav~ng a peripheral length of a filament length
corresponding to the difference between the extruding
speed of the reRpective filaments snd the falling
speed in water will be sequentially continuou~ly formed
to be coil-llke on the water surface by thi~ re~istance.
At thls time, in order to make it easy to form
loops and t~ make bent irregular loops, it is effecti~e
to keep boiling the cooling water surface between the
lncllned panels.
This boiIing state vibrates the re~pective
filament~ wound on the water surace. A~ a re~ult,
entangled di~arranged coiled loops are lnduced on the
water surface.
In order to make the boiling state on the
water surface between the lnclined guide panel~, it i8
important to keep the fllament~ coming out of the
die at a high temperature until the liquid level.
Generally, when the fllaments are in contact with the
atmosphere, the filament temperature will quickly
reduce. The water surface heated by the falling in
water of the fllamente bundle kept at a filament
extruding molding temperature of 200 to 150C. by the
above mentioned heating t~eatment to prevent air cool~
ing ln the filament coming out of the die will be
in the boiling state. Therefore, when the cooling
water i~ kept at a high temperature o~ 60 to 80C.,
this boiling will be made positive.
When the filamento are molded to be coiled
loops while kept at~a high temperature, the fu~ing
between the loops will be accel~rated ~urther, when
the cooling water is at a high temperature, in ca~e
the molded loops are pulled out into the atmosphere
by the guide roll~ and are sent to the ~econdary proce~,
they wlll be able to be easily dr1ed with cool or hot
alr.
A f~lament loop aggregation in which the
coil densit~ is made coarse by increasing the rotation
(pulllng speed in water) of the rolls in water and is
made high by reducing the pulllng ~peed is formed.
By the way, in order to strengthen the fila-
ment fusing between the coil and loop and strengthen
the durability of the coil itselt, it is effect1ve to
coat the aggregations with a bonding agent, Thereby,
the entlre filament loop aggregatlon~ can be streng-
thened and i~ 1~ effective to prevent the permanent
set of the upright coil part,
A vlnyl plastisol is generally used for
the bonding agent in thls ca~e. The strength and dura-
- 8 -
~ 6
bility of the mat can be increased by adopting a vinyl
plastisol adapted to the materlals of the mat and
shet,
It i8 effecti~e to use a plastlsol of the
same material mixture as of the filaments for the
bonding agent. The bonding agent reduced in the vi~-
cosity by addlng 20 to 30% plasticizer to the filament
material i8 sprayed or painted or has the above men-
tioned aggregation dlpped in its liquid bath, has then
the excess plastisol removed with rollers, is then
heated at 170 to 150C, with a dryer to be melted
and i8 bonded to the filament surfaces of the aggrega-
t~on to acce~erate the rus~ng bond between the ftlaments,
By the way, a vinyl plastisol is made by adding
a plastici~er and varlous ~tabilizers to a powdery vinyl
and can be used for the above mentioned object.
On the other hand, eren if the thickness
width of the hanglng filament bundle 1B not regulated,
a three-dlmensional formatlon of a colled loop will be
able to be made. However, the size of the loop formed
on the liqu~d surface 19 not flxed. Therefore, a ~eans
Or regulating the thlckness width of the filament
bundle functlons effectively to make unlform coiled
three-dlmensional aggregatlons of an intended thickness.
The entlre ~ncllned panel is of a ~tainles~
3 2 ~
steel plate or the part exposed above the eooling
water surface may be of a ~tainless ~teel plate and
the part in the cooling water may be of a ~tainle~
steel screen plate, It i9 effective that the panel
angle on the watex surface i8 held to be 45 to 80
degrees ln order to reflect the radiation heat from
the h~at source and to ~lide into water the filaments
having fallen onto the panel surface.
It is effective to ~eep the temperature of
the inclined panel at 100 to 130C.
By ad~ustlng the opposed clearances of a pair
of opposed inclined panel~ and rolls in water, various
modlf~ed aggregationB of ~ coiled loop three-dimen~ional
structure can be continuously molded,
Rotary rollera expo~ed in a part of the peri-
pheral ~urface on the water surface can be applied
instead of such inclined panels, However, ln this
case, the radiation heat reflectlng actlon wlll be 80
little as to require a heat source to cope wlth lt.
In molding synthetlc reslns, the general
temperature as of the cooling bath 19 about 50C. for
PE (polyethylene) and PP (polypropylene), about 10 to
40C. for PVC (polyvinyl chloride) and about 85C. for
PS (ploystyrene).
~ he ~urface tenslon of water on PVC (polyvinyl
- 10 -
chloride) i8 80 high as to be about 60 to 70 dym./cm.
that fine filaments of an out ide diameter less than
lmm, will be overl3pped in turn above the water surface,
the co~led loops formed here will be lamlnated in
several 8tep8 and will be coo~ed in water and there-
fore the ob~ect aggregations coarse in the loop clearances
will not be obtained. lherefore, in order to sequen-
tially sink the coiled loop8 on the liquid ~urface,
it is effective to add a surface active agent reducing
the surface tsn~ion o~ the cooling bath.
Embodiments:
Fig, 1 is a side vlew showing component parts
in an optlmum apparatu~ for embodylng the present
lnvention. ~our filaments 2 are to fall vertlcally
toward coollng water5 w~ being m~ded ~n the thickne~s
d~rection (longitudina~ direction) from a die ~
extrudlng a thermoplastic synthetlc rcsln materlal
under pressure.
In the lateral dlrectlon ~front to back
dlrectlon on the paper surface) of the T-die in thls
case, many filaments 2 are to be molded as arranged
at predetermined intervals (pitch of 3 to 5 mm.) in
the length zone corresponding to the lateral width of
an intended molding.
In the falling zone of the~e fllaments 2,
- 11
bar-like c-eramic far infrared ray heater~ 3 are arranged
on both ~ldes of the fllament bundle 80 as to be heating
heat sources. Laterally long inclined panel~ 4 are
arranged respectively below the~e heaters 3.
The above mentloned inclined panel 4 con-
slsts of an upper piece 4a of a horizontal angle ~
set in the range of 45 to 80 degrees and a lower piece
4b submerged below the water surface of the cooling
water 5. ~he lower piece~4b are arranged ~o as to
hold the above mentioned fllament bundle from both
sides and the panels 4 are formed 80 a3 to be ad~ustably
movable toward the center of the fllament bundle from
both eldes.
As a result, the filament bund~e wi~l be
limited in the thicknes~ wldth by the above mentioned
panels 4 in the zone rsaching the water ~urface of the
cooling water 5, further the outside filaments 2 of the
bundle will fall onto the upper parts 4a of the panels 4,
will sllde on the upper parts 4a and will be submerged
into the cooling water 5.
Further, submerged rollers 6 formed movably in
the direction of the above mentioned thickness width
as operatively connected with the above mentioned panel~
4 are arranged in the cooling water 5, have many engaging
pins 7 for ~topp~ng slldlng erected on the peri-
- 12 -
2 ~
pheral surfaces of the rollers 6, periodically rotate
in the winding direction indicated by the arrow in the
same drawing and are controlled ln the rotating speed
to be lower than the falling speed of the above men-
tioned filament~ 2.
Therefore, as the respective filaments 2
falling from the die 1 at a high speed are reduced
in the sinking speed in water by the above mentioned
submerged rollers 6, they will be relaxed by the fila-
ment length corresponding to the difference between
the falling ~peed and ~lnklng speed. ~hese relaxations
will concentPate in the water surface ~one due to the
buoyancy of the fila~entc 2 o a ~mall specific gravity.
a resu~t, the flla~ent~ 2 w~ orm loop~ on the
water ~urface.
This state is shown ln Fig. 2. That is to say,
the filaments 2 extruded out of the die will reach the
water surface of the cooling water 5 wh~le being kept
near the temperature ~t the time of moldlng by heating
by the above mentioned heaters 3 ln the falling zone
in alr and by the reflected heat from the upper parts 4a
of the lnclined panel~ 4. ~he filaments 2 having sunk
in the cooling water 5 will quickly lower ln the tem-
perature and will be harden~d. However, the~e hardened
filament~ 2 will be regulated in the pulling amount~ by
the submerged rollers 6 stopped ln sliding by the
engaging pins 7, therefor~ the hardened parts in water
will be sub~ected to resistances from the submerged
rollers 5 and thereby the soft filaments 2 still at a
high temperature ~ust before reachlng the water surface
will be curved and will be gradually pulled into water
while describing loops to form colled loops.
When the temperature within the bath of this
cool~ng water 5 is kept at 60 to 80C., the cooling
water 5 between the above mentioned inclined panels 4
will be locally boilded by heating by the filament~ 2
reaching the water surface while at a high temperature.
By this boiling, the water surface of that part will
be waved and greatly rocked and therefore the filaments
2 de~criblng loops on thl~ water surface will be waved
and disarranged in response to the rocking of the water
surface .
Therefore, the total surface contact will be
obstructed by the concavo-convexes by thls disarrange-
ment between the ad~acent loops of the disarranged
forms overlapped on the water surface and the contact
point parts will be comparatively many.
In such contact part. loops will be fused with
each other between them and wlll bè cooled to be hardened.
Therefore, coiled loops having com~aratively many fused
parts between the ad~acent loops will be continuou~ly
formed in turn and a mat sheet (See Fig. 4(a)) consisting
of a filament loop aggregation A in which coiled loops a1
are cross-linked longitudlnally and laterally with
loop edges overlapping between ad~acent filaments 2
will be formed.
As understandable from the ~tructure of the
above mentioned illu~trated aggregation A, in the
aggregat~on A ~n which the re~pective loops are formed
horizontally at the tlme of the above mentloned working,
the above mentioned respective loops will rise in the
upright direction when the co~tinuou~ body is used as
hor~o~ta~ ly placed,
On the other hand, a~ shown in the above
mentloned ~ig. 2, the outslde filament~ 2 hardened o~
the upper part 4a of the panel 4 by entering toward
the center from outside the filament bundle ~alling
on the inclined panel 4 will descrlbe loops on the
810pe of the part 4a, will be heaped up, wlll therefore
slip down lnto the coollng water 5 along the above
mentioned part 4a whlle the ad~acent loops are substan-
tially close to the total surface contact and will
be hardened. Therefore, as shown in the same drawing,
these fllament parts will become layers of a high
fi~ament denslty consistlng of a loop dlrectlon at right
- 15 -
-, ...
~ 9~
angles with the above described coiled loop a1 by
the other center part filaments 2 and will be fueed
with each other on the contact ~urface of the coiled
loop a1-
Therefore, as shown ln Fig. 4(b), the filamentloop aggregation A wlll become an aggregation of the
above mentioned layer consistlng of a loop a2 late-
rally fallen on one side of the above mentioned coiled
loop a~.
When the movement wlthin the filament bundle
o the above mentioned inc~ined panel 4 i8 ad~usted and
the above mentioned laterally fallen loop a2 is formed
for several filaments out~lde the fllaments 2, an
aggregatian A (See Flg.4(e)) conslst~ng of the laterally
fallen loop~ a2 of thick layer~ wlll be formed and,
when the panels 4 are both moved and the above mentioned
la`terally fallen loops a2 are made for both outside
filament~ 2 of the fllament bundle, an aggregation A
(See ~ig. 4(d)) in which layerc of the laterally fallen
loops a2 are formed on both front and back sides holding
the coiled loop a1 will be formed and an aggrega~ion A
(See Fig. 4(e)) in which the entire filament bundle is
made layer~ of laterally fallen loops a2 will be able
to be formed.
By the way, the formatlon of such various
- 16 -
aggregations A i8 determlned by the correspondlng
po~itions of the bundle of tho filament~ 2 falllng
as arranged from the die 1 and of the inclined panel~
4, it i8 theoretically possible to use a dle different
in the filament extruding spaclng (nozzle pitch spacing)
for fixed guide panels be~ides the above described
operation of movlng the above mentloned panels 4.
Flg. 3 is a slde vlew of an essential part
showing another embodiment of the present lnvention
apparatus, Instead of the lncllned panels 4 in the
above mentloned embodlment, a palr o~ water contactlng
roll~ 8 exposed by sbout 10 to 20% of the diameter
above the water ~urface may be provided rotatably and
laterally movably. ~he other parts s~milar to the
respective part~ of the abo~e mentioned embod~ment ehall
bear re~pectively the ~ame reference numerals. 9 r,epre-
sents a reflecting plate.
According to this embodiment~ the thlckness
wldth of the filament~ 2 falllng from the die 1 is
regulated by th~se roll~ 8. When these rolls 8 move
toward the fllament bundle, the outside filament 2 will
fall onto the peripheral surface of the roll exposed
above the water surface to form a layer of the above
described laterally fallen loops a2 and thè layer part
will be pulled into the coollng water 5 by the above
- 17 -
~ 6
mentioned rolls 8 while rotating by the action of.
pulling it into the loop filamentsby the submerged
rollers 6
The same as in the above mentioned embodiment,
various aggregations A in ~igs. 4(a) to 4(e) can be
formed by regulating the position~ of the rolls ~ for
the filament bundle.
By the way, in order to pull the cooled
loops formed on the cooling water surface into water
without dlsturbing their form, a surface active agent i~
added into co~ling water 4.
Amounts of addltion of surface active agents
per 100 parts of water:
A~io~c sy~tem: ~kylben~ene~u1fonate: ~ to a.2 part.
Dialkylsulfo~uccinate: 1 to 0.
Nonionic system: Polyoxyethylene nonylphenol ether:
1 to 0.1
It is eff~ective to add 0.05 to 0.2% dialkyl-
sulfosucclnate which is high in the capaclty of reducing
the surface tension and in the connecting effect with a
sllght amount
Now, in thls kind of apparatus, in order to
keep the coollng bath level constant, cooling water is
circulated with a pump while being overflowed. In such
ca~e, many bubbles will be generated in an auxiliary
- 18 -
~ 3 6
tank level detecting electrode and cooling bath and
will be disadvantageou~ in molding. In this re~pect, at
the above mentioned effective component concentration
of the dialkylsulfosucclnate, manybubbles tend to be
generated. Therefore, it can be said to be optlmum to
add and use preferably 0.05 to 0.2% dialkylsulfosuccinate.
lhe thu~ formed fllament loop aggretation A
may be coated with a plastisol made of the same materlal
mixture as of the filament to prevent the bonding
strength reductlon and permanent ~et of the filament
1 OOp9 .
The apparatu& formation therefor i8 ~hown in
Fig. 5. An aggregation A pulled up from a b~th 10 of
the above mentioned cooling water 5 is fed into a
primary dryer 12 by a feeding roller and is dried at
a low temperature. In thls drying, the aggregation A
i9 still about 70C. by the cooling water 5 at a high
temperature. Therefore, the water can be comparatively
easily and posltively removed by blowing warm wind or
the like.
The dried aggregation A i8 fed into a surface
coating proces~ part 13 by the above mentioned plastisol,
is processed in the part 13 by such means as blowing,
painting or dipping, i8 then fused by high temperature
drying in a secondary dryer 14 and is wound up on a
- 19 -
wlnder 15. As shown in Pig. 6, a back sheet B consist-
lng of a resln sheet~ foamed sheet~ resin net sheet or
rubber sheet e~. may be u ed as bonded to the back surf-
ace o~ th~s aggreqation A ln respose to the ob~ect of use
of the mat or sheet.
(Formatlon Example 1)
Polyvlnyl chlorlde (PVC) (P-1300) lO0 parts
~lastlcl2er DOP Dloctyl phthalate 50
Stablli2er Dlbutyl tln laurate2 "
Cadmium stearare 0.6 part
" Barium steararQ 0.4
Coloring agent 0.1
A compound materlal o~ the abo~e mentioned
mlxture 18 molded to be fllaments by an extrudlng molder,
~ ho c~earanc~ between thQ lnclined panel3 on the
coollng water surra~e 1~ set at 15 mm. T~e filament
moldlng orlflce dlameter of the dle 18 made 0.8 mm.
The T-dle orlflce arrangement i8 ol four longltudlnal
rows at the lnter~als o~ 4 mm. and a lateral oriflce
pltch of 5 mm.
The clea~ance between the T-dle and coollng
water surface 19 5 cm. The d1e temperature 18 185C.
The dle pressure i9 90 kg,/cm2 The extrudlng pressure
1~ 190 kg./cm2. The coollng water temperature is 60
to 80C. The gulde panel temperature 19 120C, Two
- 20 -
ceramic far infrared ray heaters ol 2,5 XW each are
used. At a molding linear ~peed of 2m, per minute, 10~PB
at a ~peed of 40 cm, per minute can be made.
In this formation, by only holding the filament
bundle in its thickness wldth directlon wit~ the inclined
panels, the front and back ~urfaces o~ the aggregations
can be uniformed and the aggregations shown in Fig, 4(a)
i8 obtalned and i8 made a producb through drying and
bonding ~teps,
As the extruder dle pressure iB applied and
hot filaments are extruded into alr, the finl~hed
dimension of the fllament i8 0,2 mm, thicker than the
f~lament orif~ce of a diameter of 0,8 mm. of the
die and a filament coil structure of a diameter of 1 mm,
is made, Even if the clearance between the inclined
panels is set to be 15 mm., the aggregation molded under
the width regulation by this clearance will shrink when
the filament i8 hardened and will be therefore 13,5 to
14 mm, thick, The loop diameter i8 about 7 mm.
Under the above mentioned ~etting, when one
of the incllned panels and water rollers is moved by
2 mm, toward the center part of the fllament bundle, the
aggregation form shown in the above mentioned ~ig. 4(b)
will be formed, When it is further moved by 2 mm. in
addit~on, the aggregation form ~hown in ~ig, 4(c) will
- 21 _
J ~9~6
be able to be formed.
~ he aggregation in ~ig. 4(b) is higher in the
sdhe3lon to the floor as a mat or sheet than the aggre-
gation in Fig. 4(a), can be increased in the strength
by the laterally fallen direction loops in the aggrega-
tion, i~ hl~h in the cushioning and i9 effective.
In the mat sheet consisting of the aggrega-
tlons in Fig, 4(c), as the lateral direction coil is
double, t~e mat strength can be further increa~ed but
the cushioning property iB lower than of the aggregation
in Fig. 4~b).
(Formation ~xample 2)
PVC ~olyvinyl chloride ~P-13aO) 100 parts
Plastici~er DID~ diisodecyl phthalate 5.5 "
~K-40 Organic cadmium chelate o.5 part
Cadmium ~tearate 0,7 i~
~arium stearate 0.3
Coloring agent 0,1 "
A compound material of the above mentloned
mixture is molded wlth an extruder.
The clearahce between the inclined panels on
the cooling water surface is 15 mm. ~he clearance
between the submerged rollers is also set at 15 mm,
The filament molding orifice diameter of the die i9
~et at 0.8 mm. The T-die hole arrangement i8 of four
- 22 -
~2 ~
longitudinal rows at the intervals of 5 mm. and a lateral
oriflce pltch of 5 mm. The distance from the T-die to
the cooling water surface is 5.5 cm.
The die temperature i~ 190C. The die
pre89Ure i8 80 kg./cm2. The extruding pressure is
190 kg,/cm2. The cooling bath temperature i9 60 to
80C. The guide panel temperature 1~ 120C. Two
ceramic far infrared ray heaters of 2.5 KW each are
used. At a molding linear speed of 2 m. per~minute,
loops at a speed of 50 cm. per minute can be made.
Thereby, an aggregation ln the form shown in
Fig, 4(b) of a filament diamter of 1,1 mm,, loop diameter
of 6 to 10 mm. and aggregation th~cknes~ of 14 mm. ean be
mo~ded.
(~ormation ~xamp~e 3)
The compound material is the same as in the
Formation Example 2.
The respective clearances of the lnclined
panels and submerged rolls are made 10 mm.
The ~dle filament oriflce diameter i8 O. 4 mm.
The die orifice arrangement is of four longltudinal
rows at the lntervals of 3mm, and a lateral orifice
pitch of 305 mm. The distance from the T-die to the
cooling water surface i9 5 cm. The die temperature i~
1B5C, The d~e pre~sure is 150 ~g./cm2. The extruding
- 23 -
pressure is 180 kg./cm2. The cooling bath temperature
i9 60 to 80C, The incllned panel temperature i8
120C. Two ceramic ~ar infrared ray heaters of 2.5 KW
each are used. The linear speed of the filament is
set at 3.5 m. per minute. The feeding speed iB set
at 70 cm. per mlnute.
Thereby, an aggregatlon in the foxm shown in
~ig. 4(c) of a filament diameter of 0.5 mm., loop dia-
meter of 6 to 10 mm. and aggregation thickness of 9 mm.
i~ molded.
(Formatlon Example 4)
The compound material is the same as in the
Formation Example 1.
The die orifice arrangement i9 of four
longitudinal rows at the in~erva~s of 5 mm. and a
lateral orifice pitch of 5 mm. The inclined panel
clearance i8 set at 14 to 1~,5 mm. The distance from
the T-dle to the cooling water surface i9 5 cm.
The die orifice diameter i9 0.8 mm. The
die temperature ie 185C, The die pressure is 90 kg./cm2.
The extruding pressure is 190 kg./cm2.
Thereby, there is formed an aggregation in
the form shown in Pig. 4(d) in a sandwitch state wherein
the front and back parts of the aggregation have flat
smooth ~urfaces, upper and ~ower loops are formed in
- 24 -
the lateral dlrection and the interior i8 of a three-
dimensional coil structure. According to thi 8 aggre-
gation, there are advantage~ that, as both front and
back ~urfaces are flat and smooth and are different
from open coil-like surfaces, shoes or the like will
not catch on the surface~ in walking and the resiliency
i~ higher than of general sheets.
It can be applled to a slope for summer
skiing as another use than ~or mats.
(~ormation Example 5)
The compoun material and other settings are
the same as in the ~ormation ~xample 4. The clearance
between the inclined panels is set at 1 cm.
T~ereby, ~ fllament loop aggregation hig~ ~n
the denslty o ~uch structure a~ of pre~sed colled loops
i9 made and lc low in the reslliency but is highest in
the strength. It is sheet-like on the ~urface but i~
formed of laterally falling direction coiled loops in
the interior and is therefore adapted to the ob~ect of
a mat passing soil, sand, rain and water, Therefore,
it i8 effective for a gate in a place where many people
walk. As different from the case that the surface is
of open coils, it will not catch on shoes when walking
or will not cut ~oops,
It can be expected to be extensively utilizable
- 25 -
~ 3
for slopes for summer sklinK.
(Effects of the Invention)
Thus, according to the mat of the present
invention, as an aggregation i8 formed of irregular
form loops by winding filaments to be coil-like, the
individual clo~ed loops well develop the filament
resiliency, are of such irregular form as a wavy form
and are therefore high in the degree of contact fusing
between the ~d~acent continuous coiled l~op~ and between
the filament forming loops arranged longitudinally and
laterally and thus a mat hlgh ln the bonded degree as a
whole can be obtained. In the mat in which such loops
are formed in the upright direction, in addition to the
re~iliency of the above mentioned loops themselves,
a stiff mat resiliency can be obtained by the strength
of the bonded degree between these loops and a porch
mat or floor sheet very high in the treading touch can
be obtained.
~ he mat in whlch these loops are formed in
the laterally fallen direction iB low in the resiliency
but is high in the tensile strength and durability, has
clearance spaces sufficlent to drop the sand, dirt and
water deposited on the mat down to the lower surface and
is therefore effective to be used for a long floor
sheet ln an establishment or the like where many people
- 26 -
~ 9.~ 6
walk in and out or for a 810p~ for skllng.
Further, by combinlng snd bondlng uprlght
directlon loops and laterally fallen loops wlth each
other, there ~an be obtalned a slmpla convenient practical
mat or sheet havlng characterlstlcs of the lndivldual mat
made of both loops descrlbed abor~.
An e~tic bsck ~heet a~ pa3ted to such mat
or sheet reinforces th~ mat elast~clty and i8 90 hlgh
ln the affinity wlth the ~et floor surrace as to be
unlikely to sllde or peel off, Partlcul~rly, the sand
and water dropped on the lower ~urface can ~e recelved
by the back sheet and the ~loor surrac~ or the llke i9
not directly dlrtied.
When the dlameter of the f~la~ent ~ th~s
case 19 set to be ln th~ rang~ mentloned in clalm 5,
the practlcal strength o~ the fllament loop can be
obtained and, on the other hand, the mat can be made
hlgh in the sheet weight con~enlent to the setting
work and ln the treadlng touch.
When the ma~or dlameter of the loop of an
lrregular form i8 ad~uQted to be ln the rage mentioned
ln clalm 6, lt wlll be effective in keeping the mat
elasticity but, on the other hand, lf the ma~or diameter
of the loop is too large, a ~hoe tlp or llke will catch
on and cut the loop and such danger as fallinq down w~ 11
- 27 -
~ 9 1 6
be li~ely to be caused. Thu~, lt is not preferable.
In the method of formlng a mst or ~heet
conslstlng of ~uch fllament loop aggregati~ns, the
fllaments are lowered onto the water surface whlle
near the modllng temperature and, when th~ 9 water
~urface 18 waved by bolling, the loops formed on the
water Qurface wlll be able to be ln such irregular
forms a8 wavy forms and to be contact-fused in the
loop ln~ersectlng parta and between the 10QP9~
In addltlon, when the filament bundle falling
toward the coolln~ water surfacs 1~ regulated ln the
dlrectlon of contractlng from outslde the wldth of the
thlckness dlrection Or the bundle, the slze~ of the
respectlve loops formed of these ~ilaments wlll be able
to be unlformed and, when the contracted wldth 1~
controlled, the formatlon of comblnlng the above de~-
cribed upright dlrectlon loops and laterally fallen
loops will be able to be freely made.
When incllned panel~ are applied as these
contractlng devloes, they wlll be a~so plates for
reflectlng the radlatlon heat from hest souroes for
holdlng the temperature at the tlme of moldin~ the above
menticned fllaments, wlll be very effective tG keep
the temperature of ~ld ~ilaments and wlll be ~lmple
and effectlve devlces whlch wlll be al90 laterally
- 28 ~
J.28B~16
fallen loop forming members.
When guide rollers partly expoaed on the
water surface are used as these contractlng devices, a
heat reflecting effect will not be able to be expected
but, by the filament pulling action by the submerged
rollers drivlng the guide rollers or under free rotation,
the filament loop~ formed on the expoeed peripheral
surfaoes of the guide rollers will be able to be sunk
into cooling water with little resistance and therefore
the loop forms will not be usele~sly di~turbed. As a
result, they are very effective to form uniform loop
forms over all the range of the aggregation.
The pawled formations on the peripheral surfaces
o~ the above mentioned suhmerged rollers are deslrable
to stabili%e the speed of the filaments controlled by
them in the sinking speed.
If the distance from the die to the coollng
water surface is long, the filament temperature will
be reduced by air cooling between them. Therefore,
it is desirable to set the distance to be as short as
possible. However, if they are too ad~acent, the loop
formation on the water surface will be disturbed. There-
fore, this distance of 5 to ~0 cm. is effective.
By keeping the. temperature of the cooling
water at a comparatively hlgh temperature of 60 to
- 29 -
J.;2~ L6
80C., a local boiling state ~n which the water ~urface
on which the filament~ fall is properly waved by heating
by the filaments submerging into water can be automatic-
ally obtained. In order to smoothly sink the filaments
to prevent the loop forms from being disturbed, it is
effective to add~a surface active agent. ~y treating
the filament loop aggregation on the surface with an
adhesive, the practical strength of the mat or sheet
can be elevated.
- 3 -
