Automatic control method for door mat production

Abstract

The invention discloses an automatic control method for door mat production, which comprises the following steps: 1, a mechanical arm clamps a thermoplastic sheet and places the thermoplastic sheet in a drying oven, and the drying oven heats and softens the thermoplastic sheet; s2, a mold provided with a specific groove is selected and placed on an operation table; s3, the thermoplastic sheet subjected to heating softening treatment is moved to the mold through the mechanical arm, and the air cylinder sequentially presses the anti-skid protruding nails on the upper surface of the thermoplastic sheet. According to the automatic production line, automatic production of the door mat is achieved, operation is easy, the automation degree is high, the lower surface of the door mat makes contact with a floor, and the lower surface of the door mat corresponds to the upper surface of the thermoplastic sheet. The anti-skidding convex nails distributed on the lower surface of the door mat can effectively prevent skidding. The upper surface of the door mat corresponds to the lower surface of the thermoplastic sheet and is tightly adjacent to the surface of the mold, the grain protrusions formed on the upper surface of the door mat can effectively achieve skid resistance of the feet of a user, and meanwhile the door mat product is attractive in appearance and good in skid resistance effect.

Description

Technical Field

[0001] This invention belongs to the field of doormats and relates to an automatic control method for doormat production. Background Technology

[0002] Currently, there are two manufacturing processes for doormats. One is injection molding, but the molds used are more expensive, approximately five times the cost of vacuum forming molds. The other is vacuum forming. In vacuum forming, softened thermoplastic sheets are vacuum-adsorbed onto a male mold. The lower surface of the thermoplastic material adheres tightly to the mold. After cooling and demolding, the doormat is formed. Because the lower surface of the doormat is in close contact with the mold during the forming process, it is difficult to place anti-slip studs on the lower surface. Even if anti-slip studs are placed on the thermoplastic sheet, they will deform during the forming process, affecting the forming effect. The lack of anti-slip studs will cause the doormat to slip when subjected to force during use. In addition, the friction between the upper surface and the user's shoe sole is low, making it easy to slip. Summary of the Invention

[0003] In order to overcome at least one deficiency of the prior art, the present invention provides an automatic control method for doormat production.

[0004] To achieve the above objectives, the present invention adopts the following technical solution: an automatic control method for doormat production, comprising: 1. the following steps:

[0005] S1: The robotic arm picks up the thermoplastic sheet and places it in the drying oven, where the thermoplastic sheet is heated and softened.

[0006] S2: Select a mold with a specific groove and place it on the worktable;

[0007] S3: The robotic arm moves the heated and softened thermoplastic sheet onto the mold, and the cylinder presses the anti-slip protrusions onto the upper surface of the thermoplastic sheet in sequence.

[0008] S4: Use a vacuum suction device to suction the softened thermoplastic sheet, so that the lower surface of the softened thermoplastic sheet is tightly pressed against the mold.

[0009] S5: After cooling and shaping, demold and trim the edges to obtain a door pad with a textured surface.

[0010] Furthermore, the lower surface of the doormat contacts the floor, and the lower surface of the doormat corresponds to the upper surface of the thermoplastic sheet, while the upper surface of the doormat corresponds to the lower surface of the thermoplastic sheet.

[0011] Furthermore, the thermoplastic sheet is made of thermoplastic vulcanized rubber.

[0012] Furthermore, the vacuum pressure when the vacuum suction device suctions the softened thermoplastic sheet is -0.8MPa to -1.2MPa.

[0013] Furthermore, the cooling method for the cooling molding process is air cooling.

[0014] Furthermore, the cooling time for the thermoplastic sheet to be cooled and formed is from 2 seconds to 50 seconds.

[0015] In summary, the advantages of this invention are:

[0016] This invention enables the automated production of doormats. It is simple to operate and highly automated. The lower surface of the doormat contacts the floor and corresponds to the upper surface of the thermoplastic sheet. Anti-slip protrusions distributed on the lower surface of the doormat effectively prevent slipping. The upper surface of the doormat closely abuts the mold surface, corresponding to the lower surface of the thermoplastic sheet. The raised texture on the upper surface of the doormat effectively prevents slipping of the user's feet. Simultaneously, the doormat product is aesthetically pleasing and provides excellent anti-slip performance. Attached Figure Description

[0017] Figure 1 This is a flowchart of the doormat production process of the present invention. Detailed Implementation

[0018] The following specific examples illustrate the implementation of the present invention. Those skilled in the art can easily understand other advantages and effects of the present invention from the content disclosed in this specification. The present invention can also be implemented or applied through other different specific embodiments, and various details in this specification can also be modified or changed based on different viewpoints and applications without departing from the spirit of the present invention. It should be noted that, unless otherwise specified, the following embodiments and features described therein can be combined with each other.

[0019] It should be noted that the illustrations provided in the following embodiments are only schematic representations of the basic concept of the present invention. Therefore, the drawings only show the components related to the present invention and are not drawn according to the actual number, shape and size of the components in the actual implementation. In the actual implementation, the form, quantity and proportion of each component can be arbitrarily changed, and the layout of the components may also be more complex.

[0020] In this embodiment of the invention, all directional indicators (such as up, down, left, right, front, back, lateral, longitudinal, etc.) are only used to explain the relative positional relationship and movement of each component in a specific posture. If the specific posture changes, the directional indicator will also change accordingly.

[0021] Due to installation errors and other reasons, the parallel relationship referred to in the embodiments of the present invention may actually be an approximate parallel relationship, and the perpendicular relationship may actually be an approximate perpendicular relationship.

[0022] Example 1:

[0023] like Figure 1 As shown, an automatic control method for doormat production includes the following steps:

[0024] S1: The robotic arm picks up the thermoplastic sheet and places it in the drying oven, where the thermoplastic sheet is heated and softened.

[0025] S2: Select a mold with a specific groove and place it on the worktable;

[0026] S3: The robotic arm moves the heated and softened thermoplastic sheet onto the mold, and the cylinder presses the anti-slip protrusions onto the upper surface of the thermoplastic sheet in sequence.

[0027] S4: Use a vacuum suction device to suction the softened thermoplastic sheet, so that the lower surface of the softened thermoplastic sheet is tightly pressed against the mold.

[0028] S5: After cooling and shaping, demold and trim the edges to obtain a door pad with a textured surface.

[0029] In the production process of the doormat, thermoplastic sheets are heated until softened. A vacuum suction device is used to draw the softened thermoplastic sheet, ensuring that the lower surface of the sheet tightly adheres to the mold, and that the protrusions and patterns formed on the lower surface of the sheet, as well as the anti-slip studs arranged on the upper surface, remain unaffected. The thermoplastic sheet is then cooled and molded, and a finished doormat is formed from this sheet. The lower surface of the doormat contacts the floor and corresponds to the upper surface of the thermoplastic sheet. The anti-slip studs distributed on the lower surface of the doormat effectively prevent slipping. The upper surface of the doormat closely abuts the mold surface, corresponding to the lower surface of the thermoplastic sheet. The raised texture on the upper surface effectively prevents slipping of the user's feet, while also providing an aesthetically pleasing and effective anti-slip product.

[0030] The thermoplastic sheet material is thermoplastic vulcanized rubber (TPV). Doormats made from TPV sheets possess excellent elasticity, toughness, tear resistance, and fatigue resistance, effectively ensuring doormat quality and extending product lifespan. These doormats exhibit high chemical stability, good chemical corrosion resistance, and weather resistance, further extending product lifespan and enhancing user experience. Furthermore, TPV has a short processing cycle, with relatively fast softening heating and molding cooling during processing, significantly improving production efficiency. Moreover, this material is recyclable, saving energy, protecting the environment, and reducing production costs.

[0031] The heating temperature for softening thermoplastic vulcanizates ranges from 2°C to 248°C. The softening temperature of thermoplastic vulcanizates is between 150°C and 170°C. Setting the heating temperature between 2°C and 248°C allows for rapid and uniform heating and softening of the thermoplastic vulcanizates, enabling them to quickly reach their softening point and improving processing efficiency. Furthermore, the heating temperature is not excessively high to avoid degradation of the material's mechanical properties, loss of elasticity, color changes, etc., and to prevent material decomposition and the generation of harmful gases.

[0032] When using a vacuum suction device to suction softened thermoplastic sheets, the vacuum pressure is -0.8MPa to -1.2MPa, so that the softened thermoplastic sheets can be quickly and stably adsorbed onto the mold surface, and the lower surface of the softened thermoplastic sheets can completely abut against the upper surface of the mold to quickly form the product.

[0033] The cooling method used in the cooling process is air cooling. Air cooling can slowly and steadily reduce the temperature of thermoplastic sheets, preventing deformation caused by a rapid drop in temperature, ensuring product shape, facilitating subsequent demolding, and improving production efficiency. Furthermore, slow cooling has less thermal impact on the mold, thus extending its lifespan. In addition, air cooling requires simple and low-cost equipment.

[0034] The cooling time for thermoplastic sheet cooling and molding ranges from 2 seconds to 50 seconds. In air cooling mode, it takes approximately 2 seconds to 50 seconds for the thermoplastic sheet to cool and solidify, thus fixing its shape. This facilitates subsequent demolding, ensures product shape, prevents product deformation, and improves product quality. Furthermore, users can choose to extend or shorten the cooling time based on the thickness of the thermoplastic sheet, improving production efficiency while ensuring effective cooling and molding.

[0035] Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of them. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort should fall within the scope of protection of the present invention.

Claims

1. An automatic control method for doormat production, characterized in that: Includes the following steps: S1: The robotic arm picks up the thermoplastic sheet and places it in the drying oven, where the thermoplastic sheet is heated and softened. S2: Select a mold with a specific groove and place it on the worktable; S3: The robotic arm moves the heated and softened thermoplastic sheet onto the mold, and the cylinder presses the anti-slip protrusions onto the upper surface of the thermoplastic sheet in sequence. S4: Use a vacuum suction device to suction the softened thermoplastic sheet, so that the lower surface of the softened thermoplastic sheet is tightly pressed against the mold. S5: After cooling and shaping, demold and trim the edges to obtain a door pad with a textured surface.

2. The automatic control method for doormat production according to claim 1, characterized in that: The lower surface of the doormat is in contact with the floor, and the lower surface of the doormat corresponds to the upper surface of the thermoplastic sheet, while the upper surface of the doormat corresponds to the lower surface of the thermoplastic sheet.

3. The automatic control method for doormat production according to claim 2, characterized in that: The thermoplastic sheet is made of thermoplastic vulcanized rubber.

4. The automatic control method for doormat production according to claim 2, characterized in that: The vacuum pressure of the vacuum suction device when suctioning softened thermoplastic sheets is -0.8MPa to -1.2MPa.

5. The automatic control method for doormat production according to claim 4, characterized in that: The cooling method for the cooling molding process is air cooling.

6. The automatic control method for doormat production according to claim 4, characterized in that: The cooling time for the thermoplastic sheet to be cooled and formed is from 2 seconds to 50 seconds.

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