Mat and mat manufacturing apparatus

Abstract

An object of the present invention is to provide a mat that is transparent, does not crack or tear, and has a thin and rising structure. 【Means for Solving the Problem】The present invention for solving the above problems is a mat disposed on a floor surface adjacent to a wall, and in use, includes a mat main body portion in contact with the floor surface, a rising portion in contact with the wall, and a fold provided between the mat main body portion and the rising portion. The mat is formed from a resin composition containing a vinyl chloride-based resin and a plasticizer, and the resin composition contains 10% by mass or more and 80% by mass or less of the plasticizer.

Description

Technical Field

[0001] The present invention relates to a mat disposed on a floor surface adjacent to a wall and a manufacturing apparatus thereof.

Background Art

[0002] In recent years, in kitchens and the like of houses, mats laid on the floor are generally used for the purpose of preventing deterioration of the floor due to oil stains and water droplets and enabling comfortable standing work. Here, in the conventional mat, a gap was generated between the end of the mat and the wall, and water and dirt might enter there.

[0003] As a technique for solving the above problems, Non-Patent Document 1 discloses a kitchen mat having an L-shaped fold. The kitchen mat has a structure in which the L-shaped fold fits exactly into the gap between the kitchen and the floor, and it is difficult for dust to accumulate.

Prior Art Documents

Non-Patent Documents

[0004]

Non-Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] While such a mat is excellent in design and functionality, it is opaque, so it does not necessarily meet the demands of users who want to show the design of the floor material. The inventors of the present invention considered the production of a transparent mat while maintaining the structure that adheres to the existing wall edge without impairing the aesthetics of the floor. Here, in order to ensure transparency, it is necessary to reduce the thickness. However, when the thickness of the mat is reduced, there is a problem that cracks and tears are likely to occur during the "crease" processing formed to adhere to the wall.

[0006] An object of the present invention is to provide a mat that is transparent, does not crack or tear, and has a thin and rising structure in order to solve such problems.

Means for Solving the Problems

[0007] The present invention for solving the above problems is as follows [1] to [6].

[0008] [1] A mat disposed on the floor surface adjacent to the wall, comprising, during use, a mat body portion in contact with the floor surface, a rising portion in contact with the wall, and a crease provided between the mat body portion and the rising portion, wherein the mat is formed from a resin composition containing a vinyl chloride-based resin and a plasticizer, and the resin composition contains 10% by mass or more and 80% by mass or less of the plasticizer.

[0009] [2] The mat according to [1], having a thickness of 2 mm or less and having light transmissibility.

[0010] [3] The mat according to [1] or [2], wherein the plasticizer is a terephthalic acid ester-based plasticizer.

[0011] [4] The mat according to any one of [1] to [3], wherein the static friction coefficient of the back surface of the mat is greater than the static friction coefficient of the front surface.

[0012] [5] The mat according to any one of [1] to [4], wherein the crease is formed by applying a high frequency with an output of 50 kW or more and 200 kW or less for 10 seconds or more and 30 seconds or less.

[0013] A manufacturing apparatus for a mat according to any one of [1] to [5], comprising a convex portion for forming a fold in a sheet material made of a resin composition containing a vinyl chloride-based resin and a plasticizer, wherein in the convex portion, a high frequency can be applied at an output of 50 kW or more and 200 kW or less for 10 seconds or more and 30 seconds or less. A manufacturing apparatus for a mat.

Effect of the Invention

[0014] The mat of the present invention can prevent dirt from entering the gap between the mat and the wall while ensuring the design of the floor surface.

Brief Description of the Drawings

[0015]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Mode for Carrying Out the Invention

[0016] <Mat> Hereinafter, a mat according to an embodiment of the present invention will be described with reference to the drawings. It should be noted that the following embodiments are examples of the present invention, and the present invention is not limited to the following embodiments.

[0017] The configuration of the mat 1 according to the present embodiment will be described with reference to FIGS. 1 to 3. As shown in FIG. 1, the mat 1 includes a mat main body portion 11 that contacts the floor surface, a rising portion 12 that contacts the wall, and a fold 13 provided between the mat main body portion 11 and the rising portion 12 when in use.

[0018] The mat main body portion 11 occupies the main area of the mat 1 and serves to cover and protect the floor surface. For example, when used in a kitchen or the like, it protects the floor material from water droplets, oil stains, spills of seasonings, or impacts and scratches caused by dropped objects.

[0019] The rising portion 12 is a strip-shaped portion that is bent upward along one end in the longitudinal direction of the mat main body portion 11 via a fold line 13 during use. By abutting the rising portion 12 against, for example, the wall surface or the kicking portion of the kitchen cabinet in the kitchen, or the lower end portion of the washbasin in the washroom, and installing the mat 1, the gap generated between the floor surface and the wall or the like can be covered. With the above configuration, the intrusion of dust, hair, food scraps, water droplets, etc. into the gap can be effectively prevented, the labor for cleaning the areas where dirt tends to accumulate can be significantly reduced, and a hygienic environment can be maintained.

[0020] The fold line 13 is a portion that connects the flat mat main body portion 11 and the upward rising portion 12 and has a function for bending the mat 1 into an L shape. The fold line 13 will be described also in the description regarding the manufacturing method described later, but it is not simply a sheet material bent at an acute angle, but has a specific cross-sectional shape formed by a fold line forming process in the manufacturing process. Specifically, a concave groove extending along the longitudinal direction of the mat main body portion 11 is formed on the back surface side of the mat 1. Further, a convex portion corresponding to the concave groove extending along the longitudinal direction of the mat main body portion 11 is formed on the front surface side of the mat 1. With the above configuration, when bending into an L shape, the concentration of stress at the bottom of the groove can be alleviated, and the force required for bending can be reduced by thinning the groove portion.

[0021] The mat 1 is formed from a resin composition containing a vinyl chloride-based resin and a plasticizer.

[0022] In the present invention, the vinyl chloride resin is not particularly limited, and examples thereof include polyvinyl chloride (PVC) homopolymers. Generally, a pure PVC homopolymer resin is a white or light yellow powder, and the density is usually in the range of 1.00 to 2.00 g / cm 3 . Also, examples of other monomers copolymerizable with vinyl chloride include vinyl acetate, ethylene, propylene, acrylic esters, methacrylic esters, maleic acid, maleic anhydride, vinylidene chloride, etc. Copolymers with these monomers (for example, vinyl chloride-vinyl acetate copolymer, vinyl chloride-ethylene copolymer, etc.) can also be used. These vinyl chloride resins may be used alone or in combination of two or more. In the present embodiment, a polyvinyl chloride (PVC) homopolymer is used as the vinyl chloride resin.

[0023] In the present invention, the lower limit value of the average degree of polymerization of the vinyl chloride resin is preferably 1000 or more, more preferably 1500 or more, still more preferably 2000 or more, and even more preferably 2500 or more. With the above configuration, since it has excellent transparency, toughness, heat resistance, and durability, sufficient strength can be maintained even when the mat is thinned.

[0024] In the present invention, the upper limit value of the average degree of polymerization of the vinyl chloride resin is preferably 5000 or less, more preferably 4500 or less, still more preferably 4000 or less, and even more preferably 3500 or less. With the above configuration, the processability is improved, and the formation of folds during manufacturing becomes easy.

[0025] In the present invention, the plasticizer is not particularly limited, but a plasticizer generally used for vinyl chloride resins can be used. For example, phthalate plasticizers, terephthalate plasticizers, adipate plasticizers, trimellitate plasticizers, polyester plasticizers, phosphate plasticizers, epoxidized vegetable oil plasticizers, citrate plasticizers, sebacate plasticizers, azelate plasticizers, sulfonate plasticizers, and the like can be used.

[0026] Examples of terephthalate plasticizers include dioctyl terephthalate (DOTP), bis(2-ethylhexyl) terephthalate, and the like. In the present invention, it is preferable to use dioctyl terephthalate as the plasticizer.

[0027] In the present invention, the resin composition contains 10% by mass or more and 80% by mass or less of the plasticizer, preferably 10% by mass or more and 70% by mass or less, more preferably 10% by mass or more and 60% by mass or less. By setting such a blending ratio, it is possible to suppress breakage and cutting during fold formation while maintaining strength and providing sufficient flexibility and permeability to the mat.

[0028] In the present invention, various additives can be blended into the resin composition as necessary within a range that does not impair the effects of the present invention. For example, stabilizers (heat stabilizers, light stabilizers, etc.) for preventing thermal decomposition during processing and use, lubricants for reducing friction between materials and enhancing the gloss of the product surface, fillers (calcium carbonate, talc, silica, etc.) for enhancing the rigidity of the material, flame retardants, antistatic agents, antibacterial agents, antifungal agents, foaming agents, impact-resistant modifiers, colorants, ultraviolet absorbers, and the like. These additives can be appropriately selected and blended according to the performance required for the kitchen mat. More preferably, the resin composition contains a stabilizer, a lubricant, and a filler.

[0029] The thickness of Mat 1 is preferably 0.5 mm or more and 4 mm or less, more preferably 0.5 mm or more and 3 mm or less, still more preferably 0.5 mm or more and 2 mm or less, and even more preferably 1 mm or more and 2 mm or less.

[0030] Mat 1 preferably has light transmissivity. Specifically, the total light transmittance measured in accordance with JIS K7361-1 is preferably 70% or more, more preferably 75% or more, and still more preferably 80% or more. With the above configuration, even when the mat is laid, it is possible to visually grasp the pattern and texture of the floor material, and it can be used without impairing the design of the indoor space. Note that the mat used in the present invention may not only be entirely transparent, but may also be a colored transparent one or a processed one such as printed on a transparent material.

[0031] The width of Mat 1 in the short side direction is not particularly limited, but it can be appropriately set preferably in the range of 40 cm or more and 70 cm or less.

[0032] The width of Mat 1 in the long side direction is not particularly limited, but it is preferably 90 cm or more and 270 cm or less, and more preferably it can be appropriately set in the range of 100 cm or more and 250 cm or less.

[0033] The width of the rising part 12 provided on Mat 1 in the short side direction is not particularly limited, but it can be appropriately set preferably in the range of 1 cm or more and 3 cm or less.

[0034] It is preferable that the surface of Mat 1 is subjected to a surface treatment for reducing stickiness. Examples of the surface treatment include processing for forming fine irregularities on the surface such as embossing, blasting, and etching.

[0035] It is preferable that the back surface of Mat 1 is not subjected to uneven formation processing such as embossing. With the above configuration, the static friction coefficient of the back surface is made larger than that of the front surface, making it difficult to slip. When the mat 1 is laid on the floor surface, the back surface can be closely attached to the floor material surface over a wide area. Further, the fold line 13 is formed thinner than the mat body portion 11 by providing a concave portion from the back surface side toward the front surface side. In the embodiment, when the mat body portion 11 and the rising portion 12 are placed horizontally, it is provided so as to protrude to the front surface side rather than the mat body portion 11. Thereby, in a state where the rising portion 12 is raised, a gap is generated between the fold line 13 and the corner of the installation portion, facilitating the installation. Further, by inclining the fold line 13 in the installed state, it is difficult for foreign matter to accumulate at the boundary between the mat body portion 11 and the fold line 13.

[0036] <Method for manufacturing a mat> Next, a method for manufacturing the mat 1 according to the embodiment of the present invention will be described. Regarding the preferred form of the mat 1, the matters described in the above <Mat> can be incorporated.

[0037] The manufacturing method of the present embodiment includes at least a step of preparing a sheet material made of a resin composition containing a vinyl chloride-based resin and a plasticizer (sheet preparation step), and a step of forming a fold line 13 in the sheet material (fold line forming step).

[0038] (Sheet preparation step) First, a predetermined blending amount of a vinyl chloride-based resin, a plasticizer, and various additives blended as necessary are prepared. These raw materials are uniformly mixed using a mixer such as a super mixer. Next, the obtained mixture is formed into a sheet shape using a known method such as a calender molding method or an extrusion molding method. At this time, by adjusting the temperature, interval, and take-up speed of the rolls, a sheet material having a desired thickness and light transmittance is obtained.

[0039] Also, in this sheet forming process, a surface treatment can be performed to reduce the stickiness on the surface (the side where the mat is used). For example, in the case of calendar forming, a desired embossing pattern can be formed on the surface of the final roll or the cooling roll, and thus the pattern can be transferred to the sheet surface. On the other hand, the back surface (the side in contact with the floor) is made into a smooth surface without any particular processing. The obtained sheet material is cut into a predetermined size as needed.

[0040] (Fold forming process) Next, a fold 13 that serves as the boundary between the mat main body 11 and the rising part 12 is formed on the prepared sheet material. This fold forming process is performed using a high-frequency welder. A high-frequency welder is a device that applies a high-frequency electric field to a dielectric and causes self-heating by the molecular motion inside the dielectric.

[0041] As a specific procedure, first, the sheet material is placed on a flat pedestal (a base made of a lower electrode or a heat insulator, etc.). Next, the linear convex part provided on the upper mold (upper electrode) of the high-frequency welder is pressed against the position where the fold of the sheet material is to be formed from directly above. This convex part has a linear shape corresponding to the finally formed fold 13.

[0042] With the sheet material pressed by the convex part, the high-frequency welder is operated, and high-frequency energy is selectively applied to the linear region where the convex part is in contact and its vicinity. As a result, the resin composition of the part pressed by the convex part is rapidly and uniformly heated from the inside and softened. By this heating and pressing, a groove-shaped thin part (fold) corresponding to the shape of the convex part is formed in the sheet material.

[0043] Here, the inventors of the present invention have intensively studied the conditions for forming sharp and durable folds without causing cracks, tears, or excessive melting or discoloration, particularly for sheet materials that are thin and require light transmissibility. As a result, it has been found that it is extremely important to set the output of the high-frequency welder in the range of 50 kW or more and 200 kW or less, and the application time (welding time) of the high frequency in the range of 10 seconds or more and 30 seconds or less.

[0044] If the output is less than 50 kW or the time is less than 10 seconds, the sheet material, particularly the inside thereof, is not sufficiently heated, resulting in insufficient softening and being prone to cracking and whitening due to inability to withstand the bending stress. On the other hand, if the output exceeds 200 kW or the time exceeds 30 seconds, the sheet material may be overheated, melted, and lose its shape, or discoloration such as charring and yellowing may occur, impairing the transparency, or the strength may decrease, making the folded part brittle.

[0045] The lower limit value of the output of the high-frequency welder is preferably 125 kW or more, more preferably 130 kW or more, more preferably 135 kW or more, more preferably 140 kW or more, and still more preferably 145 kW or more.

[0046] The upper limit value of the output of the high-frequency welder is preferably 175 kW or less, more preferably 170 kW or less, more preferably 165 kW or less, more preferably 160 kW or less, and still more preferably 155 kW or less.

[0047] The lower limit value of the application time of the high frequency is preferably 13 seconds or more, more preferably 14 seconds or more, and more preferably 15 seconds or more.

[0048] The upper limit value of the application time of the high frequency is preferably 19 seconds or less, more preferably 18 seconds or less, and more preferably 17 seconds or less.

[0049] By performing high-frequency heating within the output and time ranges specified in the present invention, even for a thin and transparent sheet material, energy can be appropriately applied without excess or deficiency, and the crease portion can be softened moderately. Therefore, a crease can be precisely and stably formed without causing cracks, breaks, or appearance defects.

[0050] After the application of high-frequency is completed, the crease portion is cooled and solidified while maintaining pressure for a predetermined time (cooling time), or by using a cooling mechanism. Then, the mold is opened, and the mat 1 with the crease 13 formed is taken out.

[0051] Through the above steps, the mat 1 of the present invention is manufactured. If necessary, a final inspection process and a packaging process are added.

[0052] <Mat Manufacturing Apparatus> The manufacturing apparatus for the mat 1 according to the embodiment of the present invention will be described. Regarding the preferred form of the mat 1 and the preferred manufacturing method of the mat 1, the matters described in the above <Mat> and <Mat Manufacturing Method> can be incorporated by reference.

[0053] The manufacturing apparatus of the present embodiment is provided with a convex portion for forming a crease 13 that is thinner than the periphery by pressing a sheet material made of a resin composition containing at least a vinyl chloride-based resin and a plasticizer. In the convex portion, high-frequency can be applied with an output of 50 kW or more and 200 kW or less for 10 seconds or more and 30 seconds or less.

[0054] The manufacturing apparatus of the present embodiment is preferably a high-frequency welding machine.

[0055] <Modification Example> It should be noted that the above embodiment can also be configured by making the following modifications. As shown in FIG. 4, the mat 2 of the modified example includes, during use, a mat main body portion 21 that contacts the floor surface, a rising portion 22 that contacts the wall, and a fold line 23 provided between the mat main body portion 21 and the rising portion 22. The fold line 23 is provided recessed with respect to the mat main body portion 21 and the rising portion 22, and the recessed direction is taken as the recess axis. In the modified example, the angle with respect to the recess axis of the fold line 23 is different between the mat main body portion 21 and the rising portion 22. Note that the recess axis is the same as the thickness direction of the fold line 23. Further, the angle formed by the mat main body portion 21 and the rising portion 22 is an obtuse angle. With the above configuration, the repulsion when the rising portion 22 contacts the wall is reduced, and the mat 2 can be made difficult to shift. Further, the angle at which the mat main body portion 21 and the rising portion 22 are deformed in the vicinity of the fold line 23 is reduced, and the durability is enhanced.

[0056] Also, it is preferable that the back surface of the mat main body portion 21 and the back surface of the fold line 23 are on the same plane. Thereby, installation with a gentle inclination angle of the fold line 23 at the time of installation can be facilitated.

[0057] Regarding the preferred form of the mat 2, the description of the above <mat> can be incorporated.

Industrial Applicability

[0058] The mat and the mat manufacturing apparatus according to the present invention can be applied to the field of a transparent floor protection material installed along a wall such as a kitchen mat, and are expected to be used in the manufacturing and sales industries of household goods and the like.

Explanation of Signs

[0059] 1, 2 Mats 11, 21 Mat main body portions 12, 22 Rising portions 13, 23 Fold lines

Claims

1. A mat for placement on a floor surface adjacent to a wall, comprising: The mat has a main body that contacts a floor surface, a rising portion that contacts a wall, and a fold that is provided between the main body and the rising portion when in use, The mat is molded from a resin composition containing a vinyl chloride resin and a plasticizer, The resin composition contains a plasticizer in an amount of 10% by mass or more and 80% by mass or less.

2. The mat according to claim 1 , wherein the mat has a thickness of 2 mm or less and is light-transmitting.

3. The mat according to claim 1 or 2, wherein the plasticizer is a terephthalic acid ester-based plasticizer.

4. The mat according to claim 1 or 2, wherein the static friction coefficient of the back surface of the mat is greater than the static friction coefficient of the front surface of the mat.

5. 3. The mat according to claim 1, wherein the folds are formed by applying high-frequency waves at an output of 50 kW or more and 200 kW or less for 10 seconds or more and 30 seconds or less.

6. The mat manufacturing apparatus according to claim 1 or 2, A sheet material made of a resin composition containing a vinyl chloride resin and a plasticizer is provided with a protrusion for forming a fold, The mat manufacturing apparatus is capable of applying high frequency power to the convex portion at an output of 50 kW or more and 200 kW or less for 10 seconds or more and 30 seconds or less.

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