Patent Application
20250135735
The present application claims the benefit of Chinese Patent Application No. 202311387407.X filed on Oct. 25, 2023, the contents of which are incorporated herein by reference in their entirety.
The present invention relates to the field of floor mat technology, involving a non-slip mat and its production system and method.
The indoor floor mat's anti-slip performance is particularly important for the elderly and children. There are frequent safety accidents in China where the users slip and fall due to the use of floor mats. Those made of rubber or latex foam materials have high safety risks on wet floors in toilets, kitchens, etc.
The floor mat can be prevented from slipping by setting the suction cup. Nowadays, the suction cup is usually connected to the floor mat through adhesive bonding, injection molding and other techniques, but most of floor mats are in the damp environment. After repeated use for many times, the suction cup is prone to fall off, which greatly affects the service life of floor mats with suction cups.
During the production process, the floor mats with suction cups require the manual participation in the fabric alignment process. Whether the fabric is aligned will affect the quality of the finished floor mats. However, after a long period of single repetitive work, the working personnel's vision and energy are prone to feel tired, so as to easily cause the problem of fabric misalignment, and affect the production efficiency and quality of floor mats with suction cups.
The present invention provides a non-slip mat and its production system and method to overcome the shortcomings of existing technologies.
In order to achieve the above purpose, the present invention adopts the following technical proposal: A non-slip mat production system is used to produce non-slip mats. The non-slip mat is composed of a surface layer, a substrate, and a suction cup. There is a hot melt unit, a pressing unit, and a positioning unit. The hot melt unit is connected to the pressing unit, and consists of a hot melt device and a hot melt table. The hot melt device conducts the fusion for the substrate; the hot melt table is provided with the movable mould; the substrate is placed on the movable mould. The positioning unit carries out the positioning and installation for the suction cup; the surface layer and suction cup are respectively put on both sides of the molten substrate. The pressing unit performs the pressing for the surface layer and suction cup, so that they are synchronously molten and welded together with the substrate to form the non-slip mat.
Further, the movable mould is provided with a perforation. The positioning unit is equipped with several suction cup positioning holes. The suction cup positioning hole is loaded with the suction cup. The perforation of the movable mould is corresponding to the suction cup positioning hole.
Further, the pressing device includes an air cylinder, a chassis, a pressing plate, and a pressing table. The air cylinder is fixed on the chassis, the pressing plate is installed at the output end of the air cylinder, the pressing table is below the pressing plate, the pressing plate driven by the air cylinder vertically moves up and down over the pressing table, and the positioning unit is set on the pressing table.
Further, a visual unit is included, composed of a controller, as well as a first camera, a second camera, an image processor and an alarm connected to the controller. The first and second cameras are respectively connected to the image processor, and the controller can control the shooting of the first and second cameras. The first and second cameras collect images to generate corresponding image signals and send image signals to the image processor. The image processor can process the images and output the processing signals to the controller. Based on the processing signals, the controller outputs the trigger signals to the alarm so as to control the start of the alarm.
Further, a cooling mechanism is also included. It can cool the semi-finished non-slip mats.
Further, there is a trimming mechanism. It includes a conveyor mechanism, a stop plate, a third camera, a visual processing module, and a trimming machine. The conveyor mechanism is located between the pressing unit and the trimming machine, connected to the pressing unit and the trimming machine. The stop plate is placed on both sides of the conveyor mechanism, to limit the location of semi-finished non-slip mats during the delivery process. The third camera is set above the trimming area, to collect the fourth image of the semi-finished non-slip mat on the trimming machine and send it to the visual processing module. The visual processing module is connected to the controller. The visual processing module receives the image and processes the fourth image to judge if the semi-finished non-slip mat is located in the trimming area and on the to-be-cut line. The center of the trimming area coincides with the centers of two cutters. When the semi-finished non-slip mat is put in the trimming area, the centers of the two have the overlapping phenomenon.
A non-slip mat production method comprises the steps of:
Further, the operation in Step 1.2 to judge if the movable mould is displaced comprises the steps of:
Further, the operation in Step 6 to judge if the semi-finished non-slip mat is located in the trimming area comprises the steps of:
In conclusion, the advantages of the present invention are as follows:
The embodiments of the present invention are described below by using the specific examples. The technicians in this field can easily understand other advantages and functions of the present invention according to the content disclosed in the specifications. The present invention can also be implemented or applied through other specific embodiments. The details in the specifications can be modified or altered based on different viewpoints and applications without deviating from the spirit of the present invention. It shall be noted that, in the absence of conflict, the following embodiments can be combined with the features in the embodiments.
It is important to point out that, the illustrations provided in the following embodiments only explain the basic conception of the present invention in a schematic manner, so they only show the components related to the present invention, and are not drawn according to the quantity, shape, and size of the components during the actual implementation. In practice, the shape, quantity, and proportion of the components can be changed at will, and the layout of the components may be more complicated.
In the embodiments of the present invention, all directional indications (including up, down, left, right, front, back, horizontal and vertical directions, etc.) are only used to explain the relative location and movement situation among components in a certain attitude. If the specific attitude has changes, the directional indications are modified accordingly.
Due to installation errors and other reasons, the parallel relationship involved in the embodiments of the present invention may actually be the approximate parallel relationship, and the vertical relationship may actually be the approximate vertical relationship.
As shown in
The surface layer 41 is made of conventional fabric, usually located on the upper layer of the non-slip mat, with water absorption capacity, and it is treated with EVA setting adhesive for high-temperature molding. The substrate 42 is made of TPE elastomer, preferably styrene TPR coating material. The hardness of the substrate 42 is 50-60 HA; the substrate 42 has strong adhesion to the surface layer to avoid the detachment between the substrate 42 and the surface layer during washing.
In the embodiment, the hot melt unit 1 includes a hot melt device and a hot melt table 11. The hot melt device conducts the fusion for substrate 42. The hot melt table 11 is used to be loaded with the substrate 42. The substrate 42 is delivered through the hot melt table 11 to the hot melt device for hot melting. The judgment of the molten state of the substrate 42 in the embodiment is that the substrate 42 is sticky, and the surface is not degreased and begins to smoke.
The hot melt table 11 is provided with the positioning line. The location of the substrate 42 is set by using the positioning line.
The hot melt device adopts the conventional oven, heating plate and other heating devices to conduct the hot melting for the substrate 42. The hot melt temperature and hot melt time can be correspondingly adjusted according to the material of the substrate 42.
The production system includes a movable mould 5. The movable mould 5 is provided with a perforation 51. The movable mould 5 is loaded with the substrate 42. The outline dimension of the movable mould 5 is matched with that of the substrate 42. The hot melt unit 1 is connected to the pressing unit 2. The movable mould 5 is located between the hot melt unit 1 and the pressing unit 2. The operator moves the movable mould 5 on the hot melt unit 1, the molten substrate 42, and the surface layer 41 to the pressing unit 2.
The pressing device 2 includes an air cylinder 20, a chassis 21, a pressing plate 22, and a pressing table 23. The air cylinder 20 is fixed on the chassis 21, the pressing plate 22 is installed at the output end of the air cylinder 20, the pressing table 23 is below the pressing plate 22, the pressing plate 22 driven by the air cylinder 20 vertically moves up and down over the pressing table 23, and the positioning unit 3 is set on the pressing table 23.
The pressing unit 2 performs the pressing for the substrate 42, the surface layer 41 and the suction cup 43, so that the surface layer 41 and the suction cup 43 are synchronously molten and welded together with the molten substrate 41 at a time to form the semi-finished non-slip mat. Compared with the conventional scheme that the existing suction cup is molded on the substrate which is attached to the surface layer through touch fasteners, the present application overcomes the disadvantage of the conventional scheme that cannot achieve the integrated welding and forming of the suction cup, substrate, and surface layer, which simplifies the non-slip mat production process, and improves the work efficiency. Compared with the conventional scheme, the hot melt and welding connection method enables the welding area among the suction cup, surface layer and substrate to have strong tear strength, which greatly enhances the service life of the non-slip mat.
Preferably, the pressing pressure of the air cylinder 20 is set to be 3 MPa, and the pressing time is set to be 5 s, to ensure that the suction cup 43 and the surface layer 42 are fully molten and welded with the substrate 42 when the surface layer 41 is not flattened.
The positioning unit 3 is provided with several suction cup positioning holes 31, the perforation 51 of the movable mould is corresponding to the suction cup positioning hole 31, and the diameter of the perforation 51 is more than that of the suction cup 43, convenient to separate the movable mould 5 after the non-slip mat is cooled and shaped. The movable mould 5 is matched with the outline dimension of the positioning unit 3. When the movable mould 5 is attached to the positioning unit 3, as long as their side edges are aligned, it can be achieved to match the perforation 51 with the suction cup positioning hole 31, convenient for workers to match the perforation 51 with the suction cup positioning hole 31 one by one. The structure is simple, and the operation is convenient.
The suction cup positioning hole 31 is loaded with the suction cup 43. The suction cup 43 includes the fixed end connected to the substrate 42, and the adsorption end used for adsorption. The suction cup 43 is installed on the suction cup positioning hole 31, with the fixed end on the top and the adsorption end at the bottom. The fixed end of the suction cup 43 is aligned with the surface of the positioning unit 3, so that the fixed end of the suction cup 43 can be in direct contact with the molten substrate 42 carried by the positioning unit 3.
In order to ensure the stability of the loading of the suction cup 43 on the positioning unit 3, the suction cup positioning hole 31 is provided with the positioning block, and the outer diameter of the positioning block is less than the inner diameter of the absorption end of the suction cup 43. When the suction cup 43 is loaded, the positioning block is located inside the absorption end, to locate the loading of the suction cup 43.
The visual unit is composed of a controller, as well as a first camera, a second camera, an image processor and an alarm connected to the controller. The first and second cameras are respectively connected to the image processor, and the controller can control the shooting of the first and second cameras. The first and second cameras collect images to generate corresponding image signals and send image signals to the image processor. The image processor can process the images and output the processing signals to the controller. Based on the processing signals, the controller outputs the trigger signals to the alarm so as to control the start of the alarm.
The first camera is set over the hot melt table 11, used to collect the images of the hot melt table 11, including the initial image of the movable mould 5 on the hot melt table 11, the first image of the first integrated body constituted due to the connection between the movable mould 5 and the substrate 42, and the second image of the second integrated body formed by attaching the surface layer 41 on the first integrated body. The image processor receives the image and processes the initial image, the first image and the second image to judge if the location of the movable mould 5, the substrate 42 and the surface layer 41 is correct. If it is not on the set position, the alarm will be activated to remind the working personnel to conduct the rearrangement.
The second camera is located above the positioning unit 3, used to collect the third image of the second integrated body on the positioning unit 3. The image processor receives the third image and processes the third image to judge if the location of the second integrated body is correct. If it is not on the set position, the alarm will be activated to remind the working personnel to conduct the rearrangement.
The production system also includes a cooling mechanism. The cooling mechanism cools the semi-finished non-slip mat to 60° C. The semi-finished non-slip mat is demoulded after cooling.
The production system also contains a trimming mechanism that cuts the excess substrate 42 on the semi-finished non-slip mat to obtain the finished non-slip mat. It includes a conveyor mechanism, a stop plate, a third camera, a visual processing module, and a trimming machine. The conveyor mechanism is located between the pressing unit 2 and the trimming machine, connected to the pressing unit 2 and the trimming machine. The conveyor mechanism delivers the semi-finished non-slip mat from the pressing unit 2 to the trimming machine. The stop plate is placed on both sides of the conveyor mechanism, to limit the location of semi-finished non-slip mats during the delivery process, so as to prevent the deviation of semi-finished non-slip mats. The trimming machine is provided with the conveyor, to move the semi-finished non-slip mat to the trimming area. The third camera is set above the trimming area, to collect the fourth image of the semi-finished non-slip mat on the trimming machine and send it to the visual processing module. The visual processing module is connected to the controller. The visual processing module receives the image and processes the fourth image to judge if the semi-finished non-slip mat is located in the trimming area and on the to-be-cut line. The center of the trimming area coincides with the centers of two cutters. When the semi-finished non-slip mat is put in the trimming area, the centers of the two have the overlapping phenomenon. If it is not in the trimming area, and the conveyor of the trimming machine drives the semi-finished non-slip mat to move the corresponding distance to check if the semi-finished non-slip mat is in the trimming area, or the conveyor mechanism or/and the conveyor of the trimming machine is judged to be faulted due to multiple dislocation of semi-finished non-slip mats, then the controller suspends the conveyor mechanism or/and the conveyor of the trimming machine, to activate the alarm.
The trimming machine includes a cutter, a cutter displacement mechanism, a cutting rotation mechanism, and a cutting drive mechanism. There are two cutters that are respectively connected to the cutter displacement mechanism. The cutter displacement mechanism controls the movement of the cutter to the position of the to-be-cut line; it is put in the cutting rotation mechanism that controls the rotation of the cutter and the cutter displacement mechanism by 90°. The cutting rotation mechanism is located in the cutting drive mechanism that controls the downward movement of the cutter along the to-be-cut line to obtain the finished non-slip mat.
During the implementation process of the embodiment, the movable mould 5 is placed on the hot melt table 11, the first camera collects the initial image of the movable mould 5 on the hot melt table 11, and the image processor can process the initial image, to judge if the movable mould 5 is on the set position. The set position of the movable mould 5 is that the movable mould 5 is located within the positioning line of the hot melt table 11; if not, the alarm is activated to remind the working personnel to conduct the rearrangement, until the movable mould 5 is on the set position. The substrate 42 is placed on the movable mould 5. The first camera collects the first image of the first integrated body. The image processor can process the first image, to judge if the location of the substrate 42 on the movable mould 5 is on the set position. The set position of the substrate 42 is that the substrate 42 is aligned with the movable mould 5; if not, the alarm is activated to remind the working personnel to conduct the rearrangement, until the substrate 42 is located on the set position. The hot melt table 11 delivers the movable mould 5 and the substrate 42 to the hot melt device for hot melting. When the substrate 42 is in a molten state, the movable mould 5 and the substrate 42 are separated from the hot melt device. The surface layer 41 is placed on the molten substrate 42. The first camera collects the second image of the second integrated body, and the image processor can process the second image to judge if the surface layer 41 is on the set position; if not, the alarm is activated to remind the working personnel to conduct the rearrangement, until the surface layer 41 is located on the set position. The surface layer 41 is set to be in the middle of the substrate 42. The suction cup 43 is loaded on the positioning unit 3. The second integrated body moves to the positioning unit 3. The second camera collects the third image. The image processor can process the third image, to judge if the second integrated body is on the set position; if not, the alarm is activated to remind the working personnel to conduct the rearrangement, until the second integrated body is located on the set position. The set position of the second integrated body can ensure that the movable mould 5 is aligned with the positioning unit 3. At this time, the perforation 51 of the movable mould 5 is corresponding to the suction cup positioning hole 31 of the positioning unit 3. It is required to start the air cylinder 20, press down the pressing plate 22, and compress the second integrated body, so that the surface layer 41 and the suction cup 42 are molten and welded with the molten substrate 41 to obtain the semi-finished non-slip mat. The cooling mechanism cools the semi-finished non-slip mat. The semi-finished non-slip mat is demoulded after cooling. The trimming mechanism cuts the excess substrate 42 on the semi-finished non-slip mat to obtain the finished non-slip mat.
As shown in
In Step 1, the specific operation to place the movable mould 5 and the substrate 41 on the set position of the hot melt table 11 comprises the steps of:
In Step 1.4, the specific operation to judge if the substrate 42 is displaced comprises the steps of:
In Step 3, the operation to place the surface layer 41 on the set position of the substrate 42 comprises the steps of:
In Step 6, the operation to judge if the semi-finished non-slip mat is located in the trimming area comprises the steps of:
L=H1×S; W=H2×S;
L=H1×S; W=H2×S;
Obviously, the described embodiments are only part of the embodiments of the present invention, not all of them. Based on the embodiments of the present invention, all other embodiments obtained by general technicians without creative labor shall fall within the protection scope of the present invention.
| Number | Date | Country | Kind |
|---|---|---|---|
| 202311387407.X | Oct 2023 | CN | national |
