JPH076848Y2 - Floor mat - Google Patents
Floor matInfo
- Publication number
- JPH076848Y2 JPH076848Y2 JP1990006513U JP651390U JPH076848Y2 JP H076848 Y2 JPH076848 Y2 JP H076848Y2 JP 1990006513 U JP1990006513 U JP 1990006513U JP 651390 U JP651390 U JP 651390U JP H076848 Y2 JPH076848 Y2 JP H076848Y2
- Authority
- JP
- Japan
- Prior art keywords
- mat
- rubber
- rubber sheet
- foaming
- sheet
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Lifetime
Links
- 229920001971 elastomer Polymers 0.000 claims description 79
- 239000005060 rubber Substances 0.000 claims description 79
- 239000004744 fabric Substances 0.000 claims description 27
- 238000005187 foaming Methods 0.000 claims description 22
- 239000000835 fiber Substances 0.000 description 24
- 238000005406 washing Methods 0.000 description 16
- 230000008602 contraction Effects 0.000 description 10
- 239000007789 gas Substances 0.000 description 10
- 238000010438 heat treatment Methods 0.000 description 10
- 238000000034 method Methods 0.000 description 10
- 238000004064 recycling Methods 0.000 description 10
- 238000001035 drying Methods 0.000 description 8
- 230000008569 process Effects 0.000 description 8
- 230000008859 change Effects 0.000 description 6
- 239000000203 mixture Substances 0.000 description 6
- 239000004088 foaming agent Substances 0.000 description 5
- 238000004519 manufacturing process Methods 0.000 description 5
- 238000012856 packing Methods 0.000 description 5
- 239000007787 solid Substances 0.000 description 5
- 239000006260 foam Substances 0.000 description 4
- 239000000463 material Substances 0.000 description 4
- 238000003825 pressing Methods 0.000 description 4
- 229920005989 resin Polymers 0.000 description 4
- 239000011347 resin Substances 0.000 description 4
- 229920003051 synthetic elastomer Polymers 0.000 description 4
- 239000005061 synthetic rubber Substances 0.000 description 4
- 229920001821 foam rubber Polymers 0.000 description 3
- 229920000728 polyester Polymers 0.000 description 3
- 238000009732 tufting Methods 0.000 description 3
- 238000004073 vulcanization Methods 0.000 description 3
- 244000043261 Hevea brasiliensis Species 0.000 description 2
- 238000004140 cleaning Methods 0.000 description 2
- 230000007423 decrease Effects 0.000 description 2
- 230000007547 defect Effects 0.000 description 2
- 239000000428 dust Substances 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 239000005038 ethylene vinyl acetate Substances 0.000 description 2
- 229920003052 natural elastomer Polymers 0.000 description 2
- 229920001194 natural rubber Polymers 0.000 description 2
- 239000004745 nonwoven fabric Substances 0.000 description 2
- 229920001778 nylon Polymers 0.000 description 2
- 229920001200 poly(ethylene-vinyl acetate) Polymers 0.000 description 2
- 229920000915 polyvinyl chloride Polymers 0.000 description 2
- 239000004800 polyvinyl chloride Substances 0.000 description 2
- 229920002972 Acrylic fiber Polymers 0.000 description 1
- 239000004156 Azodicarbonamide Substances 0.000 description 1
- 229920000742 Cotton Polymers 0.000 description 1
- 239000004677 Nylon Substances 0.000 description 1
- 229920002292 Nylon 6 Polymers 0.000 description 1
- BZHJMEDXRYGGRV-UHFFFAOYSA-N Vinyl chloride Chemical compound ClC=C BZHJMEDXRYGGRV-UHFFFAOYSA-N 0.000 description 1
- 229920002978 Vinylon Polymers 0.000 description 1
- 230000005856 abnormality Effects 0.000 description 1
- 238000005299 abrasion Methods 0.000 description 1
- 238000010521 absorption reaction Methods 0.000 description 1
- XOZUGNYVDXMRKW-AATRIKPKSA-N azodicarbonamide Chemical compound NC(=O)\N=N\C(N)=O XOZUGNYVDXMRKW-AATRIKPKSA-N 0.000 description 1
- 235000019399 azodicarbonamide Nutrition 0.000 description 1
- 230000008901 benefit Effects 0.000 description 1
- NTXGQCSETZTARF-UHFFFAOYSA-N buta-1,3-diene;prop-2-enenitrile Chemical compound C=CC=C.C=CC#N NTXGQCSETZTARF-UHFFFAOYSA-N 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 239000000470 constituent Substances 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 230000002950 deficient Effects 0.000 description 1
- 210000005069 ears Anatomy 0.000 description 1
- 239000001257 hydrogen Substances 0.000 description 1
- 229910052739 hydrogen Inorganic materials 0.000 description 1
- 230000007774 longterm Effects 0.000 description 1
- 230000014759 maintenance of location Effects 0.000 description 1
- 230000001617 migratory effect Effects 0.000 description 1
- 230000004660 morphological change Effects 0.000 description 1
- 125000002560 nitrile group Chemical group 0.000 description 1
- 238000000059 patterning Methods 0.000 description 1
- 230000000704 physical effect Effects 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 230000000717 retained effect Effects 0.000 description 1
- 230000009291 secondary effect Effects 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
- 239000013585 weight reducing agent Substances 0.000 description 1
Landscapes
- Passenger Equipment (AREA)
- Carpets (AREA)
- Laminated Bodies (AREA)
Description
【考案の詳細な説明】 （産業上の利用分野） この考案は、床マット、特に住居、店舗等の玄関、人口
等に敷設して靴底等の除塵の目的に使用される床マット
に関する。DETAILED DESCRIPTION OF THE INVENTION (Industrial field of application) The present invention relates to a floor mat, particularly a floor mat that is laid at the entrance of a house, a store, etc., and used to remove dust such as shoe soles.
（従来の技術） 床マットは、基布にパイル系をタフト化し、合成ゴムの
パッキングによりタフト系を固定したものが多く、店
舗、住居、事務所等で戸外から室内へのダストの侵入を
防止する目的で、これらの出入口付近に敷かれて使用さ
れている。(Prior art) Many floor mats are made of tufted pile fabric on the base fabric and fixed with synthetic rubber packing to prevent dust from entering the room from the outside in stores, houses, offices, etc. It is laid and used near these entrances for the purpose of doing.
合成ゴムのパッキングは通常、タフト化されたパイル系
と未加硫ゴムシートを重ね合わせ、加熱、加圧すること
で一体化させる方法が一般に用いられる。また床マット
は、ゴムのパッキングの代りにポリ塩化ビニール等の発
泡体シートをパッキングしたものが知られている。The packing of synthetic rubber is generally performed by a method in which a tufted pile system and an unvulcanized rubber sheet are superposed and integrated by heating and pressing. In addition, as the floor mat, it is known that a foam sheet such as polyvinyl chloride is packed instead of the rubber packing.
（考案が解決しようとする問題点） このような方法でマットを製造する場合、マット原反
部、及びゴム部の両者の寸法は加熱加圧時に固定され冷
却後、通常の使用温度では、ゴムと繊維の線膨張率の違
いからひずみを生じるか、あるいは、内部応力として残
存することとなり、結果として両者の差が波うち、カー
ル等の形態変化として現われる。(Problems to be solved by the invention) When a mat is manufactured by such a method, the dimensions of both the mat raw material part and the rubber part are fixed at the time of heating and pressurizing, and after cooling, at the normal operating temperature, the rubber is not used. The difference between the linear expansion coefficients of the fiber and the fiber causes strain or remains as internal stress. As a result, the difference between the two appears as a morphological change such as waviness and curl.
また、これらの初期マット製造時の寸法差に加えて、く
り返し使用による（洗浄、乾燥のくり返しによる）繊維
の収縮（ゴム体は繊維と比較して収縮しにくい）による
ひずみが加わる事により、マット全体として複雑にひず
みが生じることとなり、最終的に波うち、カール等の不
良発生の原因となる。また、これらのことはレンタルマ
ットではマットの寿命を短くすることとなるため大きな
問題となる。In addition to these dimensional differences during the initial mat production, strain due to fiber shrinkage due to repeated use (due to repeated washing and drying) (rubber bodies are less likely to shrink than fibers) adds to the mat. As a whole, distortion is generated in a complicated manner, which eventually causes defects such as waviness and curl. In addition, these problems become a big problem in the rental mat because it shortens the life of the mat.
また、ソリッドゴムに代えてポリ塩化ビニール等の発泡
樹脂シートを使用したものは、この発泡樹脂シートの発
泡倍率（発泡後の体積と発泡前の体積との比率）が大き
くて５倍以上であり、かつ発泡樹脂シートのスキン層が
薄くて0.05mm以下であったので、ソリッドゴム製に比べ
て非常に軽い反面、強度が低くて破損し易く、かつ耐熱
性が低く、そのため洗浄し加熱乾燥すると、２〜３回の
洗浄で破損し、また床に対するフィット性が低いという
問題があった。Further, in the case where a foamed resin sheet such as polyvinyl chloride is used instead of the solid rubber, the foaming ratio of this foamed resin sheet (the ratio of the volume after foaming to the volume before foaming) is 5 times or more. And, since the skin layer of the foamed resin sheet was thin and was 0.05 mm or less, it was very light compared with the solid rubber, but it had low strength and was easily damaged, and had low heat resistance. However, there was a problem that it was damaged by washing 2 to 3 times, and the fitting property to the floor was low.
従って本考案の目的は、これらのマット製造時の加熱、
加圧により生じる繊維とゴムの寸法差を無くすこととそ
の後のくり返し使用による繊維の収縮による波うち、カ
ール等の発生を防止し、かつゴム付一体マットで問題と
なる重量も軽減することが可能で床に対するフィット性
が良好な一体化マットを提供するにある。Therefore, the purpose of the present invention is to heat the mats during manufacturing,
It is possible to eliminate the dimensional difference between the fiber and rubber caused by pressurization, to prevent waviness and curl due to the contraction of the fiber after repeated use, and to reduce the problematic weight with the rubber integrated mat. The purpose is to provide an integrated mat with a good fit to the floor.
（問題点を解決するための手段） 本考案によれば、基布と、該基布にタフト化されたマッ
トパイルと、該基布の裏面に一体化されたゴムシートか
らなる床マットにおいて、低発泡性の未加硫ゴムシート
とタフト化マットとを加熱加圧下に一体化させ且つ該ゴ
ムシートを加硫発泡させることにより形成され、ゴムシ
ートは1.2乃至３倍の発泡倍率を有し且つ0.1乃至1.0mm
の厚みのスキン層を有することを特徴とする波うちを防
止した床マットが提供される。(Means for Solving the Problems) According to the present invention, in a floor mat comprising a base fabric, a mat pile tufted on the base fabric, and a rubber sheet integrated on the back surface of the base fabric, It is formed by integrating a low-foaming unvulcanized rubber sheet and a tufted mat under heat and pressure and vulcanizing and foaming the rubber sheet, and the rubber sheet has a foaming ratio of 1.2 to 3 times and 0.1 to 1.0 mm
There is provided a corrugated floor mat having a skin layer having a thickness of about 1.
（作用） 本考案の床マットは、公知の床マットと同様に、基布
と、基布にタフト化されたマットパイルと、この基布の
裏面（非パイル面）に一体化されたゴムシートとから成
るが、低発泡性の未加硫ゴムシートとタフト化マットと
を加熱加圧下に一体化させ且つこのゴムシートを加硫発
泡させること、及びこのゴムシートを1.2乃至３倍の発
泡倍率を有するように低発泡させ且つ0.1乃至1.0mmの厚
みのスキン層を有するようにすることが顕著な特徴であ
る。(Function) The floor mat of the present invention is similar to a known floor mat, and includes a base cloth, a mat pile tufted into the base cloth, and a rubber sheet integrated with the back surface (non-pile surface) of the base cloth. A low-foaming unvulcanized rubber sheet and a tufted mat are integrated under heat and pressure, and the rubber sheet is vulcanized and foamed, and the rubber sheet has a foaming ratio of 1.2 to 3 times. It is a remarkable feature that it has a low foaming ratio so that it has a skin layer having a thickness of 0.1 to 1.0 mm.
従来の一体化マットにおける各工程での寸法変化を説明
する第２図において、工程（Ａ）において、基布にパイ
ルをタフト化して成る原反１をゴムシート２と重ね合
せ、工程（Ｂ）で重ね合せたものを加熱加圧して、両者
の接着による一体化とゴムシートの加硫とを行い、最後
に工程（Ｃ）で冷却する。即ち、プレス時にゴムシート
が熱膨張した後、繊維とゴムが接着、固定されその後冷
却されることにより、ゴムの熱収縮と原布の熱収縮の差
がマットのカール波うち、内部ひずみの原因となる（初
期状態）。かくして、プレス時の寸法を基準とすると、
波うちの原因となる収縮量の差は、式 収縮量差（Ｓ）＝ゴムの熱収縮長さ−基布の熱収縮長さ で表わされる。In FIG. 2 for explaining the dimensional change in each step in the conventional integrated mat, in step (A), a raw fabric 1 formed by tufting piles on a base fabric is superposed on a rubber sheet 2, and then step (B). The materials superposed in step (1) are heated and pressed to integrate them by adhesion and vulcanize the rubber sheet, and finally cooled in step (C). That is, after the rubber sheet thermally expands during pressing, the fibers and rubber are bonded and fixed, and then cooled, so that the difference between the thermal contraction of the rubber and the thermal contraction of the base cloth causes the internal distortion of the curl wave of the mat. Becomes (initial state). Thus, based on the dimensions when pressing,
The difference in the amount of shrinkage that causes waviness is expressed by the formula: difference in amount of shrinkage (S) = heat shrinkage length of rubber−heat shrinkage length of base cloth.
またその後レンタルマットとしてくり返し使用されるこ
とにより、洗浄、乾燥等のリサイクル工程により繊維の
収縮が発生する。また繊維に比べゴムは洗浄、乾燥等の
リサイクル工程では収縮が少ないため、これらの差は大
きく広がることになる。Further, after that, it is repeatedly used as a rental mat, so that the fiber shrinks due to a recycling process such as washing and drying. Further, since the rubber is less shrunk in the recycling process such as washing and drying as compared with the fiber, the difference between them is greatly widened.
リサイクル工程での収縮を説明するための第３図におい
て、この収縮では、基布1bとゴム２＋パイルバック
ステッチ３の２つの相対的な関係でバイメタルの様に作
用すると考えられ、パイルのバックステッチは繊維の長
さ方向に収縮する。結果としてくり返し使用によるパイ
ルのバックステッチの収縮は前述したマット製造時のゴ
ムの収縮（熱）にプラスされ、基布1bの相対差が大きく
なる。In Fig. 3 for explaining the shrinkage in the recycling process, in this shrinkage, it is considered that the base cloth 1b and the rubber 2 + pile backstitch 3 act like bimetals due to the two relative relationships. Shrinks along the length of the fiber. As a result, the contraction of the back stitch of the pile due to repeated use is added to the contraction (heat) of the rubber at the time of manufacturing the mat, and the relative difference of the base fabric 1b becomes large.
かくして、リサイクル工程後での収縮量の差（Ｒ）は式 Ｒ＝Ｓ｛基布の洗浄後の収縮長さ−（ゴムの洗浄後の収
縮長さ−パイルステッチの収縮長さ）｝ で表わされることになる。Thus, the difference in shrinkage amount (R) after the recycling process is expressed by the formula R = S {shrinkage length of the base cloth after washing- (shrinkage length of the rubber after washing-shrinkage length of pile stitch)}. Will be done.
従来の一体化マットでは、上記２つの要因により波う
ち、カールを発生し、レンタルマットとして長期に安定
して使用するには問題を生じることになる。In the conventional integrated mat, undulations and curls occur due to the above two factors, which causes a problem for stable and long-term use as a rental mat.
本考案では、これら各マット構成素材の収縮挙動を考慮
し、マット一体加工時の加圧加熱加工において発泡構造
をゴム部に導入することにより、加圧加熱後の収縮、洗
浄、乾燥によるマットの収縮を緩和することに成功し、
波うちが発生しないゴム付マットが得られた。また副次
的な効果として、同一ゴムシート厚を用いた場合、従来
の固型ゴムタイプと比較して軽量化タイプとすることが
可能となり、レンタルマットとしてクリーニングコスト
のダウンも可能となった。その理由を以下に説明する。In the present invention, in consideration of the shrinkage behavior of each of the mat constituent materials, by introducing a foamed structure into the rubber portion in the pressure heating process during the mat integral processing, the mat after shrinkage, washing and drying after the pressure heating is applied. Succeeded in alleviating the contraction,
A rubber mat without waviness was obtained. As a secondary effect, when the same rubber sheet thickness is used, it is possible to make the type lighter than the conventional solid rubber type and to reduce the cleaning cost as a rental mat. The reason will be described below.
一般に密閉気体はボイルーシャルルの法則で示されてい
る様に“加熱により体積膨張”、“加圧により体積減
少”する。これらの変化量については気体を理想気体と
みなした場合式 PV＝nRTまたは 式中、P,P1，P2は気体の圧力、V,V1，V2は気体の容積、
T,T1，T2は気体の温度（゜Ｋ）Ｒは気体定数、ｎは気体
のモル数である、 の関係が成り立つ。In general, a closed gas "volume expands by heating" and "volume decreases by pressurization" as shown by Boyle-Charles' law. For these changes, when the gas is regarded as an ideal gas, the equation PV = nRT or Where P, P 1 and P 2 are gas pressures, V, V 1 and V 2 are gas volumes,
T, T 1 and T 2 are the temperature (° K) of the gas, R is the gas constant, and n is the number of moles of the gas.
かくして、ゴムシート中の気泡の容積（体積）は、温度
及び圧力によって上記式で表わされるように変化する。
一方、ゴムシート及び繊維では、加圧による体積変化は
無視できるが、加熱による容積変化（寸法変化）が前述
したようにあり、床マット用素材として使用されるポリ
エステル繊維、ナイロン繊維、アクリル繊維、ビニロン
繊維、綿等の天然繊維ではそれぞれ固有の線膨張率があ
るが、ゴム体のそれ（例えばNBRの場合13〜20×10-5，
℃-1）に比べれば小さい。Thus, the volume (volume) of the bubbles in the rubber sheet changes as represented by the above formula depending on the temperature and the pressure.
On the other hand, in rubber sheets and fibers, volume change due to pressurization can be ignored, but volume change (dimensional change) due to heating is as described above, and polyester fiber, nylon fiber, acrylic fiber, which is used as a floor mat material, Vinylon fibers and natural fibers such as cotton have their own linear expansion coefficients, but that of rubber bodies (for example, NBR 13 to 20 × 10 -5 ,
It is smaller than ℃ -1 ).
本考案の発泡ゴム付マットにおいては、加圧によるゴム
／繊維接着を行う際、加圧下から常圧にまで結果的に減
圧されるため、これらの圧力差を利用して、ゴム中の気
泡を体積増加させ、マット全体のアンバランスな収縮を
防止することができ、結果として波うち防止することが
できる。In the foamed rubber mat according to the present invention, when the rubber / fiber is bonded by pressurization, the pressure is reduced as a result from under pressure to normal pressure. The volume can be increased and unbalanced shrinkage of the entire mat can be prevented, and as a result, waviness can be prevented.
詳細に はゴムの熱収縮、気泡の熱収縮、繊維の洗浄収縮と比べ
体積変化の大きい気泡の膨張を利用することにより、こ
れらの収縮のアンバランスを解消することが可能となっ
た。Specifically, it was possible to eliminate the imbalance of these contractions by utilizing the thermal contraction of rubber, the thermal contraction of bubbles, and the expansion of bubbles whose volume change is larger than the contraction by washing of fibers.
一般のゴムパッキングマットと比べ、ゴムの熱膨張時に
同時に発泡反応を実施することにより、加熱加圧時にゴ
ム中に密閉状態で気体を保持させ、ゴム−繊維を固定さ
せる。この後常温、常圧に戻った時に圧力差に応じてゴ
ム部の膨張（気体の膨張）を発生させることにより使用
時に平面状のカールを防止したマットを得ることが可能
となる。Compared with a general rubber packing mat, a foaming reaction is carried out at the same time when the rubber is thermally expanded, so that a gas is held in the rubber in a sealed state and a rubber-fiber is fixed during heating and pressurization. After that, when the temperature returns to normal temperature and pressure, expansion of the rubber portion (expansion of gas) is generated in accordance with the pressure difference, so that it is possible to obtain a mat in which flat curl is prevented during use.
本考案のマットの製造工程を示す第４図において工程
（Ａ）において基布にパイルをタフト化して成る原反１
を、発泡剤及び加硫剤を含有する低発泡性の未加硫ゴム
シート２と重ね合せ、工程（Ｂ）で重ね合せたものを加
熱加圧して、両者の接着による一体化とゴムシートの加
硫発泡とを行わせる。この際ゴムシート２には、気泡４
が形成される。最後に工程（Ｃ）でパッキングマットを
冷却する。In FIG. 4 showing the manufacturing process of the mat of the present invention, a raw fabric 1 formed by tufting piles into a base cloth in the step (A).
Is superposed with a low-foaming unvulcanized rubber sheet 2 containing a foaming agent and a vulcanizing agent, and the one superposed in step (B) is heated and pressed to integrate the two by bonding and Vulcanization and foaming is performed. At this time, bubbles 4 are formed on the rubber sheet 2.
Is formed. Finally, in step (C), the packing mat is cooled.
工程（Ｂ）と工程（Ｃ）との間で ゴムの熱収縮＝圧力減による体積膨張 とすることにより、通常のゴム付マットのカールを防止
できる。Curling of the usual rubber mat can be prevented by heat shrinkage of rubber = volume expansion due to pressure reduction between the steps (B) and (C).
この時のゴムシート２の発泡状態は、微細な独立気泡が
一様に密に分布した発泡構造を有する。The foamed state of the rubber sheet 2 at this time has a foamed structure in which fine closed cells are uniformly and densely distributed.
本考案においては、ゴムシートの発泡倍率が1.2乃至３
倍の範囲にあるようにする。発泡倍率が1.2倍を下まわ
るとゴム付マットのカール防止が十分でなくなり、また
軽量化が十分に果せない。また発泡倍率が３倍を上まわ
ると強度が十分でなくなり耐久性が低下する。In the present invention, the expansion ratio of the rubber sheet is 1.2 to 3
Be in the double range. If the expansion ratio is less than 1.2 times, the mat with rubber will not be sufficiently curled and the weight cannot be reduced sufficiently. If the expansion ratio exceeds 3 times, the strength will be insufficient and the durability will decrease.
リサイクル過程における洗浄、乾燥の繰返しに対しても
上記発泡倍率の範囲が波うち、カールの発生防止に好適
である。発泡倍率が1.2倍を下まわるとゴムシートが強
く繊維の収縮を吸収、緩和できなくなる。また発泡倍率
が３倍をこえると繊維の収縮を吸収緩和できても前記し
た通り強度が十分でなくなり耐久性が低下する。The range of the expansion ratio described above is suitable for preventing the occurrence of curling and curling even after repeated washing and drying in the recycling process. When the expansion ratio is less than 1.2 times, the rubber sheet is too strong to absorb and relax the shrinkage of the fiber. Further, if the expansion ratio exceeds 3 times, even if the shrinkage of the fiber can be absorbed and relaxed, the strength is insufficient as described above and the durability is lowered.
本考案においては、低発泡したゴムシートのスキン層の
厚みが0.1乃至1.0mmであることも重要である。スキン層
の厚みが0.1mmを下まわると、強度が十分でなく耐久性
が低下する。スキン層の厚みが1.0mmを上まわると強度
が十分であるが、強すぎてリサイクル過程における洗
浄、乾燥の繰返しによる繊維の収縮の吸収緩和が不十分
となり、また軽量化が達成できなくなる。In the present invention, it is also important that the thickness of the skin layer of the low-foamed rubber sheet is 0.1 to 1.0 mm. When the thickness of the skin layer is less than 0.1 mm, the strength is insufficient and the durability is reduced. If the thickness of the skin layer exceeds 1.0 mm, the strength will be sufficient, but it will be too strong and absorption and relaxation of fiber shrinkage due to repeated washing and drying in the recycling process will be insufficient, and weight reduction cannot be achieved.
また本考案のゴムシートは発泡状態が独立気泡のためリ
サイクル過程の洗浄の際、内部に水の浸入がないので洗
浄、乾燥を容易に行うことができる。Further, since the rubber sheet of the present invention has a closed-cell foaming state, it can be easily washed and dried because water does not enter inside during the washing process in the recycling process.
（実施例） 本考案の床マットは、第１図に示すように、パイルカー
ペット１裏面に発泡ゴムシート２をバッキングしたもの
であり、この発泡ゴムシート２が発泡倍率1.2〜３倍、
スキン層2aの厚み0.1〜1.0mmのものであることを特徴と
する。図中、1aはカットパイル、1bは繊維および不織布
等からなる基布である。(Example) As shown in FIG. 1, the floor mat of the present invention is one in which a foam rubber sheet 2 is backed on the back surface of the pile carpet 1, and the foam rubber sheet 2 has a foaming ratio of 1.2 to 3 times.
The skin layer 2a is characterized by having a thickness of 0.1 to 1.0 mm. In the figure, 1a is a cut pile, and 1b is a base fabric made of fibers, non-woven fabric, or the like.
上記の発泡ゴムシートは、天然ゴム製または合成ゴム製
のいずれでもよく、その好ましい厚みは0.5〜2.0mmであ
る。そして、この考案の床マットは、例えば上記の天然
ゴムまたは合成ゴムからなるゴム組成物に発泡剤を加え
てシートを形成し、このシート上にパイルカーペットを
重ねて熱板間に挟み、３〜5kg/cm2の圧力下、150〜170
℃で10〜20分間加熱し、加硫発泡させることにより製造
される。この場合に使用する発泡剤は、アゾジカルボン
アミド、パラトルエンスルホニルヒドラジッド等の低臭
気性のものが好ましく、その添加量は0.1〜5.0重量部が
好ましい。なお、パイルカーペットの裏面には、あらか
じめエチレン酢酸ビニル共重合体を塗布して発泡ゴムシ
ートとの接着性を高めることができる。また、熱板で挟
む際は、熱板との間に繊維シートを介在させることがで
きる。The foamed rubber sheet may be made of natural rubber or synthetic rubber, and its preferable thickness is 0.5 to 2.0 mm. The floor mat of the present invention is formed by adding a foaming agent to the above rubber composition made of natural rubber or synthetic rubber to form a sheet, stacking a pile carpet on the sheet, and sandwiching the sheet between hot plates. under a pressure of 5kg / cm 2, 150~170
It is produced by heating at 10 ° C for 10 to 20 minutes and vulcanizing and foaming. The foaming agent used in this case is preferably one having a low odor, such as azodicarbonamide and paratoluenesulfonylhydrazide, and the addition amount thereof is preferably 0.1 to 5.0 parts by weight. It should be noted that the back surface of the pile carpet can be coated with an ethylene vinyl acetate copolymer in advance to enhance the adhesiveness with the foamed rubber sheet. Further, when sandwiched between the hot plates, a fiber sheet can be interposed between the hot plates.
また、ゴム組成物としては、アクリロニトリルブタンジ
エンゴム（NBR）を用いることが特に好ましい。NBRは、
機械的強度、耐熱性、耐油性、耐候性等に優れているば
かりでなく、ニトリル基による強い水素結合のため、気
泡の保持性が大であり、洗浄・乾燥等のリサイクル工程
でも安定に発泡構造が保持され、優れた波打ち防止効果
と床に対するフィット性が得られるという利点がある。It is particularly preferable to use acrylonitrile butanediene rubber (NBR) as the rubber composition. NBR is
Not only is it excellent in mechanical strength, heat resistance, oil resistance, weather resistance, etc., but also has strong air bubble retention due to strong hydrogen bonding by the nitrile group, and stable foaming even in recycling processes such as washing and drying. There is an advantage that the structure is retained and an excellent anti-waviness effect and a fit property to the floor are obtained.
実施例１ 下記第１表の組成を有するゴム組成物を使用して厚さ1.
0mmの未加硫ゴムシートを成形した。Example 1 Using a rubber composition having the composition shown in Table 1 below, thickness 1.
A 0 mm unvulcanized rubber sheet was molded.
一方、ポリエステル繊維製不織布の基布1bにナイロンバ
ルキー加工糸のパイル糸をタフティングして高さ10mmの
カットパイル1aを形成し、基布1bの裏面にエチレン酢酸
ビニル共重合体をコーティングしてパイルカーペット１
を用意した。そして、第５図に示すように、上記の未加
硫ゴムシート２上にこのパイルカーペット１を置き、こ
れらを２枚の熱板５間に模様付け用繊維シート６を介し
て挟み、4kg/cm2の圧力下、160℃で15分間の加硫を行
い、本考案の床マットを得た。この床マットの発泡ゴム
シート２は、発泡倍率1.7倍、スキン層2aの厚み0.2mm、
全厚み1.7mmであり、得られたマットの全重量は2360g/m
2であり、フィット性も良好で、またこのマットの洗濯
試験をしたところ、20回の繰り返し洗濯で何の異常も認
められなかった。すなわち、従来のソリッドゴムを使用
したものに比べて重量が約25％軽くなり、従来の発泡塩
化ビニルシートを使用したものに比べて耐久性が向上し
て洗濯回数が少なくとも７倍に増大した。 On the other hand, tufting pile yarns of nylon bulky yarn on the base fabric 1b made of polyester fiber to form a cut pile 1a with a height of 10 mm, and coating the backside of the base fabric 1b with an ethylene vinyl acetate copolymer. Pile carpet 1
Prepared. Then, as shown in FIG. 5, the pile carpet 1 is placed on the unvulcanized rubber sheet 2, and the pile carpet 1 is sandwiched between two hot plates 5 with a patterning fiber sheet 6 interposed therebetween. Vulcanization was performed at 160 ° C. for 15 minutes under a pressure of cm 2 to obtain a floor mat of the present invention. The foam rubber sheet 2 of this floor mat has a foaming ratio of 1.7 times, the thickness of the skin layer 2a is 0.2 mm,
The total thickness is 1.7 mm, and the total weight of the obtained mat is 2360 g / m.
It was 2 , the fit was good, and when the washing test of this mat was performed, no abnormality was observed after 20 times of repeated washing. That is, the weight was about 25% lighter than that using the conventional solid rubber, the durability was improved and the number of washings was increased at least 7 times as compared with the one using the conventional expanded vinyl chloride sheet.
実施例２ 前記第１表の組成を有するゴム組成物を、厚さ1.0mmで
発泡率が０％、50％（発泡剤1.5部含有）、100％（発泡
剤3.0部含有）である３種の未加硫ゴムシートを作製し
た。この未加硫ゴムシートを金型を用いて3kg/cm2の圧
力下、160℃で30分間の加硫を行った。シートが20℃に
冷却した後その寸法を測定した。Example 2 Three kinds of rubber compositions having the composition shown in Table 1 and having a thickness of 1.0 mm and a foaming ratio of 0%, 50% (containing 1.5 parts of a foaming agent) and 100% (containing 3.0 parts of a foaming agent). An unvulcanized rubber sheet of was prepared. This unvulcanized rubber sheet was vulcanized at 160 ° C. for 30 minutes under a pressure of 3 kg / cm 2 using a mold. The sheet was cooled to 20 ° C and its dimensions were measured.
結果を第２表に示す。The results are shown in Table 2.
ゴムシート寸法はエアー量に対しほぼ規則的に寸法変化
した。 The rubber sheet size changed substantially regularly with respect to the amount of air.
実施例３ 第３表に示すA,B2種のゴムシートを使用し、下記のマッ
ト原反を用いて第４図に示すようにプレス板４の間で離
型シート５を介して、第３表の条件で加硫してゴムシー
ト付マットを作製した。Example 3 Using the rubber sheets of A and B type 2 shown in Table 3, the following mat raw fabric was used, as shown in FIG. Vulcanization was performed under the conditions shown in the table to prepare a rubber sheet mat.
（マット原反） パイル ナイロン−６ 1300d/2ply ステッチ６、パイル高さ9mm、 ゲージ5/32、目付量880g/m2 基布 ポリエステル不織布100g/m2 上記条件で製造したマットを通行人数3000人／日の場所
に３日間敷設した後、通常の一体化マット洗浄再生処理
を行う。(Mat original fabric) Pile Nylon-6 1300d / 2ply Stitch 6, pile height 9mm, gauge 5/32, basis weight 880g / m 2 base fabric polyester non-woven fabric 100g / m 2 The mat produced under the above conditions is laid for 3 days at a place where the number of people passing by is 3000 people / day, and then the usual integrated mat washing and recycling treatment is performed.
この操作を40回くり返し行った後マット外周の波うち発
生個数と高さを測定した。また、外観の不良場所、耳破
れ、摩耗等についても同時に確認した。結果を第４表に
示す。After repeating this operation 40 times, the number of undulations and the height of the outer periphery of the mat were measured. At the same time, the location of defective appearance, tearing of the ears, wear and the like were also confirmed. The results are shown in Table 4.
ＡはＢと比較して波うちの発生が少なく、またＢのマッ
トでは波うちが多数発生し、通行時にマットが足にひっ
かかる等の問題が生じ、また非常にみぐるしい状態であ
った。 A was less wavy than B, and a lot of waviness was generated in the mat of B, causing problems such as the mat getting caught on the foot when passing, and it was also in a very migratory state.
またＡのマットでは裏面のゴム部にも摩耗等の欠陥も認
めらず、発泡ゴムシートでの物理的性質に関して問題は
認められなかった。Further, in the mat A, no defects such as abrasion were observed in the rubber portion on the back surface, and no problem was observed in the physical properties of the foamed rubber sheet.
（考案の効果） 本考案では、マット一体加工時の加圧加熱加工において
発泡構造をゴム部に導入し、カーペットのバッキング材
として発泡率1.2〜３倍、スキン層の厚み0.1〜1.0mmの
発泡ゴムシートを使用することにより、加圧加熱後の収
縮、洗浄・乾燥によるマットの収縮を緩和することに成
功し、波打ち現象を有効に防止することができた。ま
た、従来の高発泡率の発泡樹脂シートを使用したものに
比べて強度および耐熱性が上昇して耐洗濯性が大幅に向
上されて、マットの寿命を延長することができた。更に
床面に対づるフィット性が良好であると共に、従来のソ
リッドゴムシートでパッキングしたものに比べて全マッ
ト重量が大幅に軽量化されているため、取扱が容易であ
り、レンタルマットとしてクリーニングコストのダウン
も可能となった。(Effect of the invention) In the present invention, the foam structure is introduced into the rubber portion in the pressure heating process when the mat is integrally processed, and the foam ratio is 1.2 to 3 times as the backing material of the carpet, and the skin layer has the foam thickness of 0.1 to 1.0 mm. By using a rubber sheet, we succeeded in alleviating the shrinkage after heating under pressure and the shrinkage of the mat due to washing and drying, and it was possible to effectively prevent the waving phenomenon. In addition, the strength and heat resistance are increased and the washing resistance is significantly improved, and the life of the mat can be extended as compared with the conventional foamed resin sheet having a high foaming rate. Furthermore, it has a good fit with the floor surface, and the weight of the entire mat is significantly lighter than the one packed with conventional solid rubber sheets, making it easy to handle and the cleaning cost for a rental mat. It became possible to down.
第１図はこの考案の実施例の断面図であり、 第２図は従来の一体化マットにおける各工程での寸法変
化を説明するための図であり、 第３図はリサイクル工程での収縮を説明するための図で
あり、 第４図は本考案のマットの製造工程を示す図であり、 第５図は実施例におけるマットの加圧方法を説明するた
めの図である。 １…カーペット（マット原反）、1a…パイル、1b…基
布、２…ゴムシート、2a…スキン層。 （未加硫ゴムシート、発泡ゴムシート）FIG. 1 is a cross-sectional view of an embodiment of the present invention, FIG. 2 is a view for explaining a dimensional change in each step of a conventional integrated mat, and FIG. 3 shows shrinkage in a recycling step. It is a figure for explaining, Drawing 4 is a figure showing a manufacturing process of a mat of the present invention, and Drawing 5 is a figure for explaining a pressing method of a mat in an example. 1 ... Carpet (mat mat), 1a ... Pile, 1b ... Base cloth, 2 ... Rubber sheet, 2a ... Skin layer. (Unvulcanized rubber sheet, foamed rubber sheet)
Claims (2)
イルと、該基布の裏面に一体化されたゴムシートからな
る床マットにおいて、低発泡性の未加硫ゴムシートとタ
フト化マットとを加熱加圧下に一体化させ且つ該ゴムシ
ートを加硫発泡させることにより形成され、ゴムシート
は1.2乃至３倍の発泡倍率を有し且つ0.1乃至1.0mmの厚
みのスキン層を有することを特徴とする波うちを防止し
た床マット。1. A floor mat comprising a base cloth, a mat pile piled into tufts on the base cloth, and a rubber sheet integrated with the back surface of the base cloth, wherein a low foaming unvulcanized rubber sheet and tufts. Formed by vulcanizing and foaming the rubber sheet with a synthetic mat under heat and pressure, and the rubber sheet has a foaming ratio of 1.2 to 3 times and a skin layer having a thickness of 0.1 to 1.0 mm. A floor mat that prevents waviness, which is characterized by that.
ゴム（NBR）から成る請求項（１）記載の床マット。2. A foamed rubber sheet is made of nitrile-butadiene.
The floor mat according to claim 1, which is made of rubber (NBR).
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP1990006513U JPH076848Y2 (en) | 1990-01-26 | 1990-01-26 | Floor mat |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP1990006513U JPH076848Y2 (en) | 1990-01-26 | 1990-01-26 | Floor mat |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| JPH03120869U JPH03120869U (en) | 1991-12-11 |
| JPH076848Y2 true JPH076848Y2 (en) | 1995-02-22 |
Family
ID=31510189
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP1990006513U Expired - Lifetime JPH076848Y2 (en) | 1990-01-26 | 1990-01-26 | Floor mat |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JPH076848Y2 (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2010200931A (en) * | 2009-03-03 | 2010-09-16 | Kuraray Plast Co Ltd | Doormat |
Family Cites Families (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS5221232U (en) * | 1975-08-02 | 1977-02-15 |
-
1990
- 1990-01-26 JP JP1990006513U patent/JPH076848Y2/en not_active Expired - Lifetime
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2010200931A (en) * | 2009-03-03 | 2010-09-16 | Kuraray Plast Co Ltd | Doormat |
Also Published As
| Publication number | Publication date |
|---|---|
| JPH03120869U (en) | 1991-12-11 |
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