JP2000023898A - Mat and its manufacture - Google Patents

Abstract

PROBLEM TO BE SOLVED: To prevent the bleeding of an antioxidant by using an ethylene- propylene rubber compound as a rubber compound. SOLUTION: A nylon pile is implanted to a backing consisting of a polyester nonwoven fabric. Isoprene rubber latex is applied on the rear side of a nylon pile surface. A rubber compound sheet obtained by mixing rubber components and kinds of mixing agents is abutted on a mat original cloth and the sheet is heat-pressure-processed with the mat original cloth, namely the joining processing of the sheet and the mat original cloth and the bridging processing of the sheet are executed to join the bridged sheet of the rubber compound to the mat original cloth. The rubber compound is obtained by mixing a proper amount of proper bridging agent, packing material, a rubber processing agent, etc., to ethylene-propylene rubber and a proper amount of proper bridging agent can be mixed corresponding to a purpose.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a mat such as a foot-wiping mat and the like, which can prevent contact contamination to a floor material and the like.

[0002]

2. Description of the Related Art In a mat in which a mat base material is a crosslinked rubber obtained by cross-linking a rubber compound, and the mat base material is bonded to the back surface of a raw mat, conventionally, as a rubber compound , Acrylonitrile-butadiene rubber (N
BR) formulations have been used. In addition, an antioxidant was compounded in the rubber compound in order to improve the ozone resistance and weather resistance of the mat.

[0003]

By the way, the antioxidant may remain in the mat base material of the manufactured mat and may ooze out of the mat base material little by little during use of the mat. However, since many antiaging agents for rubber compounds generally become contaminants on floors on which mats are laid, exudation is not preferable. In order to prevent floor contamination due to such exudation, the types and the like of antioxidants have been intensively studied, but floor contamination may occur when adverse conditions such as the use environment and the use method overlap. Was. Therefore, there has been a demand for a mat that can prevent such oozing of contaminants.

[0004] It is an object of the present invention to provide a mat which can prevent leaching of an antiaging agent, and a method by which such a mat can be produced.

[0005]

According to the first aspect of the present invention,
A mat base material is bonded to the back surface of the mat raw material, and the mat base material is a cross-linked rubber obtained by cross-linking a rubber compound.In the mat, the rubber compound is an ethylene-propylene rubber compound. Features.

According to the first aspect of the present invention, since the mat base is made of a crosslinked rubber of an ethylene-propylene rubber compound, it is not necessary to mix an antioxidant which may cause floor contamination when compounding the rubber. In addition, the ozone resistance and weather resistance of the mat substrate are favorably maintained.

According to a second aspect of the present invention, in the first aspect of the invention, the rubber compound does not contain an antioxidant.

According to the second aspect of the present invention, since the rubber compound does not contain an antioxidant at the time of compounding the rubber, the floor is prevented from being contaminated by leaching of the antioxidant.

According to a third aspect of the present invention, in the first or second aspect, the crosslinking treatment is performed by peroxide crosslinking.

In the invention according to claim 3, since the crosslinking treatment is based on peroxide crosslinking, a suitable crosslinking speed is maintained. By the way, aldehyde ammonias, aldehyde amines, guanidines, thioureas, thiazoles, sulfenamides, dithiocarbamates, xanthates, thiurams, etc., when a crosslinking accelerator for rubber becomes a floor contaminant. In the case of a mat substrate comprising a rubber compound blended with these crosslinking accelerators, when adverse conditions overlap in the use environment and use method,
The cross-linking accelerator may ooze out of the mat substrate to cause floor contamination. However, in the invention of claim 3, since these crosslinking accelerators are not used, the floor is not contaminated due to the exudation of the crosslinking accelerator.

According to a fourth aspect of the present invention, in the third aspect of the invention, the crosslinking treatment is performed by blending a co-crosslinking agent.

In the invention of claim 4, since a co-crosslinking agent is used, the crosslinking density is improved in the peroxide crosslinking reaction, and the mat base material has improved properties such as strength, tear strength and abrasion resistance. I do.

According to a fifth aspect of the present invention, there is provided a method for producing a mat, wherein a mat base material is bonded to the back surface of the mat stock, and the mat base material is a crosslinked rubber obtained by subjecting a rubber compound to a crosslinking treatment. In the step of cross-linking the rubber compound in a state where the uncrosslinked treated sheet of the rubber compound is in contact with the back surface of the raw mat, in this step, ethylene-propylene rubber compound as the rubber compound It is characterized by being used.

In the invention of claim 5, since an ethylene-propylene rubber compound is used as the rubber compound, ozone resistance and weather resistance can be maintained without adding an anti-aging agent which causes floor contamination at the time of rubber compounding. A mat substrate having good properties is obtained.

According to a sixth aspect of the present invention, in the fifth aspect of the invention, an antiaging agent is not added to the rubber compound.

According to the sixth aspect of the present invention, since the rubber compound does not contain an antioxidant at the time of rubber compounding, floor contamination due to leaching of the antioxidant is prevented.

According to a seventh aspect of the present invention, in the above step of the fifth or sixth aspect, the crosslinking treatment is performed by peroxide crosslinking.

In the invention according to claim 7, since the crosslinking treatment is carried out by peroxide crosslinking, it is not necessary to use the above-mentioned crosslinking accelerator in order to maintain a favorable crosslinking rate.

According to an eighth aspect of the present invention, in the above step of the seventh aspect of the invention, the crosslinking treatment is carried out by blending a co-crosslinking agent.

In the invention according to claim 8, since the crosslinking treatment is carried out by blending a co-crosslinking agent, the crosslinking density is improved, and the properties of the mat base material such as strength, tear strength and abrasion resistance are improved.

In the present invention, the raw mat is usually formed by laying a pile on a base cloth and applying an appropriate amount of latex or the like as a backing material to prevent the pile from coming off. As the pile or the base cloth, various materials and structures can be used according to the purpose. Also, as latex,
Various materials and configurations can be used depending on the purpose,
In the present invention, since the rubber component in the mat base material is ethylene-propylene rubber, it is preferable to select a latex having good adhesion to the ethylene-propylene rubber. Further, various compounding agents may be added to the latex according to the purpose. The latex may have been subjected to a crosslinking treatment by an appropriate method. Further, instead of latex, liquid rubber (or liquid rubber compound) may be used. Further, when the intended purpose is not excluded, a raw mat consisting of a pile and a base cloth may be used without using latex or the like.

The rubber compound of the present invention is obtained by mixing an ethylene-propylene rubber with an appropriate amount of a crosslinking agent, a filler, a rubber processing agent and the like in an appropriate amount. A crosslinking agent may be blended in an appropriate amount.

The ethylene-propylene rubber is a concept including a copolymer of ethylene and propylene (EPM) and a copolymer of ethylene, propylene and a diene component (EPDM). EPMs generally consist of 40-60% by weight of an ethylene component and 60-40% by weight of a propylene component. EPDM is generally 40-80% by weight.
Of ethylene component, 50 to 15% by weight of propylene component and 1 to 15% by weight of diene component. As the diene component, for example, ethylidene norbornene, dicyclopentadiene, 1,4-hexadiene and the like are used. .

The ethylene-propylene rubber used in the ethylene-propylene rubber compound includes mat durability,
The mat may be selected from the above-mentioned grades of ethylene-propylene rubber in consideration of properties such as the tensile strength of the mat, the adhesion to the raw mat, and the workability and handleability of the uncrosslinked sheet of the rubber compound. Further, two or more grades of ethylene-propylene rubber may be mixed and used. Furthermore,
By mixing a rubber other than ethylene-propylene rubber to produce a rubber compound, a rubber compound suitable for the purpose can be obtained. However, ethylene used in that case-
Rubbers other than propylene rubber vary depending on the type thereof, but are preferably used in a proportion of 100 parts by weight or less based on 100 parts by weight of ethylene-propylene rubber, and when used in a higher proportion, ozone resistance and weather resistance In some cases, heat resistance and the like may be reduced or costs may be increased.

As the cross-linking agent, a peroxide cross-linking agent is preferable from the viewpoint of difficulty in causing floor contamination. As a peroxide crosslinking agent, the pot life of the uncrosslinked rubber compound sheet is not shortened, the heating temperature during the heating and pressing treatment does not need to be extremely high, and the handling during compounding is easy. From the viewpoint, 1,1-bis (t-hexylperoxy)
-3,3,5-trimethylcyclohexane, 1,1-bis (t-hexylperoxy) cyclohexane, 1,1
-Bis (t-butylperoxy) -3,3,5-trimethylcyclohexane, di-t-butylperoxy-2-
Methylcyclohexane, 1,1-bis (t-butylperoxy) cyclohexane, 1,1-bis (t-butylperoxy) cyclododecane, 2,2-bis (t-butylperoxy) butane, n-butyl- 4,4-bis (t-
Butylperoxy) valerate, 2,2-bis (4,4
Peroxyketals such as -di-t-butylperoxycyclohexyl) propane; P-menthane hydroperoxide, diisopropylbenzene hydroperoxide, 1,1,3,3-tetramethylbutyl hydroperoxide, cumene hydroperoxide; hydroperoxides such as t-hexyl hydroperoxide; α, α'-bis (t-butylperoxy) diisopropylbenzene, dicumyl peroxide, 2,5
-Dimethyl-2,5-bis (t-butylperoxy) hexane, t-butylcumyl peroxide, di-t-butyl peroxide, 2,5-dicumyl-2,5-bis (t-butylperoxy) A dialkyl peroxide such as hexine-3 is preferably used. Particularly, 1,1-bis (t-hexylperoxy)-
3,3,5-trimethylcyclohexane, 1,1-bis (t-hexylperoxy) cyclohexane, 1,1-
Bis (t-butylperoxy) -3,3,5-trimethylcyclohexane, di-t-butylperoxy-2-methylcyclohexane, 1,1-bis (t-butylperoxy) cyclohexane, 1,1-bis (T-butylperoxy) cyclododecane, 2,2-bis (t-butylperoxy) butane, n-butyl-4,4-bis (t-butylperoxy) valerate, 2,2-bis (4 4-
Di-t-butylperoxycyclohexyl) propane,
P-menthane hydroperoxide, 1,1,3,3
-Tetramethylbutyl hydroperoxide, t-hexyl hydroperoxide, 2,5-dimethyl-
2,5-bis (t-butylperoxy) hexane, di-
t-butyl peroxide, 2,5-dimethyl-2,5
-Bis (t-butylperoxy) hexyne-3 and the like are more preferably used. Furthermore, from the viewpoint that the degree of unpleasant odor generated from the mat during or after the crosslinking reaction is relatively low, 1,1-bis (t-butylperoxin)-
3,3,5-trimethylcyclohexane, n-butyl-
4,4-bis (t-butylperoxy) valerate,
2,5-dimethyl-2,5-bis (t-butylperoxy) hexane, 2,5-dimethyl-2,5-bis (t-
Butylperoxy) hexyne-3 and the like are more preferably used.

As the filler, carbon black, silica, calcium carbonate, magnesium carbonate, clay, talc, titanium oxide and the like can be used.
One of these is selected, or two or more are mixed and used.

As the rubber processing agent, various plasticizers, rubber softeners, extender oils and the like can be used, and it is preferable to select and use one having good affinity for ethylene-propylene rubber. In addition, since the rubber processing agent may ooze out of the mat base material in some cases, not only has a good affinity with the ethylene-propylene rubber, but also a colorless and transparent material or a material close to it is selected to prevent floor contamination. It is preferable to use them.

For the purpose of accelerating the crosslinking speed and improving the dispersibility of the compounding agent in the rubber compound, a crosslinking accelerating aid or an activator may be used. As these, zinc oxide, magnesium oxide, stearic acid, oleic acid, zinc stearate, diethylene glycol, and the like can be used. Depending on the purpose, one of these can be selected, or two or more can be mixed. And use it.

Suitable co-crosslinking agents include, for example, ethylene glycol dimethacrylate, trimethylolpropane trimethacrylate, ethylene dimethacrylate, polyethylene glycol dimethacrylate, cyclohexyl methacrylate, allyl methacrylate, diallyl itaconate, polyfunctional methacrylate monomer, Polyhydric alcohol methacrylate, polyhydric alcohol acrylate, N, N-methphenylene dimaleimide, triallyl cyanurate, triallyl isocyanurate, zinc methacrylate, zinc dimethacrylate, magnesium methacrylate, magnesium dimethacrylate, acrylic acid, Metal-containing monomers obtained by adding metals such as magnesium, calcium, aluminum, and zinc to methacrylic acid, maleic acid, and the like are listed. That.

The kneading of the rubber compound and the rolling of the sheet can be performed by selecting a known method, and the thickness of the sheet can be variously selected according to the purpose. Further, the thickness of the sheet or the composition of the rubber compound may be appropriately changed depending on the position of the mat.

An appropriate foaming agent may be added in an appropriate amount to the rubber compound to form the mat base material into a foam.

[0032]

BEST MODE FOR CARRYING OUT THE INVENTION Nylon piles are planted on a base cloth made of polyester non-woven fabric, and isoprene rubber latex is coated on the back side of the nylon pile surface. Comparative form 1 of Table 2
3, a rubber compound sheet obtained by compounding a rubber component and various compounding agents is brought into contact with each other, and the sheet is subjected to heat and pressure treatment together with the raw mat material. And a cross-linking treatment of the sheet was performed to obtain a mat in which a cross-linked rubber compound sheet (mat base material) was bonded to an original mat. The heating and pressurizing treatment is performed by pressing a sheet of the rubber compound on the back surface of the mat raw material with a hot plate sandwiching the sheet from above and below, and specifically,
The thickness of the rubber compound sheet is 1.3 mm, the hot plate temperature is 160 ° C., the pressing time is 20 minutes, and the pressing pressure is 3 kgf / c.
It was carried out in m ^2.

When only a sheet was manufactured for a physical property test, the following procedure was performed. That is, a cross-linked rubber is obtained by subjecting a rubber compound sheet obtained by mixing the rubber components shown in Embodiments 1 to 9 in Table 1 and Comparative Examples 1 to 3 in Table 2 to various compounding agents under heat and pressure. I got a sheet. The heating and pressing treatment is performed by pressing a sheet of the rubber compound from above and below with a hot plate, and specifically, the thickness of the sheet of the rubber compound is 1.3 mm, Temperature 16
The test was performed at 0 ° C. for 20 minutes under a pressure of 3 kgf / cm ² .

The above-mentioned rubber compound sheet was prepared by kneading the above rubber component and various compounding agents by a known method using a Banbury mixer, and rolling by a known method. In the crosslinking method, Embodiments 1 to 9 and Comparative Embodiments 2 and 3 are based on peroxide crosslinking, and Comparative Embodiment 1 is based on sulfur crosslinking.

[0035]

[Table 1]

[0036]

[Table 2]

In Tables 1 and 2, details of each component of the rubber compound are as follows. EPDM1, EPD
M2, EPM, NBR and IR are rubber components, and the others are compounding agents. EPDM 1: Oil-extended EPDM (product number: EP96) manufactured by JSR Corporation, specifically, propylene content 2
7 wt%, iodine value (base polymer iodine value) 1
9, Mooney viscosity (ML _{1 + 8} (120 ° C.)) 53, extension oil containing 50 PHR, diene component: dicyclopentadiene. -EPDM 2: EPDM manufactured by JSR Corporation (Part number:
EP75F), specifically having a propylene content of 30
wt%, iodine value 20, Mooney viscosity (ML _{1 + 4} (10
0 ° C)) 85, a diene component: ethylidene norbornene,
Stuff. -EPM: EPM manufactured by JSR Corporation (Part No .: EP1
1), specifically, a propylene content of 49 wt%,
Mooney viscosity (ML _{1 + 4} (100 ° C.)) 40.・ NBR: NBR manufactured by JSR Corporation (Part number: N230
S), specifically having a bound acrylonitrile content of 3
5 wt%, Mooney viscosity (ML _{1 + 4} (100 ° C)) 5
6, using a non-staining stabilizer.・ IR: IR made by JSR Corporation (Part number: IR220
0), specifically, a polyisoprene rubber having a cis 1,4 bond of 98% and a Mooney viscosity (ML _{1 + 4} (100 ° C.)) of 82.

Processing oil 1: A paraffin-based process oil (product number: PW380) manufactured by Idemitsu Kosan Co., Ltd. Processing oil 2: Dioctyl phthalate (DOP). Crosslinking agent 1: 2,5-dimethyl-2,5-di-t-butylperoxyhexane (40%, manufactured by NOF Corporation)
Diluted product) (trade name: Perhexa 25B-40). -Crosslinking agent 2: sulfur. -Co-crosslinking agent 1: Trimethylolpropane triacrylate (trade name: Sanester TM, manufactured by Sanshin Chemical Co., Ltd.)
P). -Co-crosslinking agent 2: sulfur. In the sixth embodiment, sulfur was used as a peroxide cross-linking co-crosslinking agent for the purpose of further increasing the cross-link density of the cross-linked rubber and improving the high elongation characteristics.・ Blowing agent: Made by Uniroyal Chemical Company
p, p'-oxybis (benzenesulfonyl hydrazide) (trade name: Cellogen OT-I).

Crosslinking accelerator 1: Mercaptobenzothiazole (trade name: Noxeller M) manufactured by Ouchi Shinko Chemical Industry Co., Ltd. Crosslinking accelerator 2: dibenzothiazyl disulfide (trade name: Noxeller D, manufactured by Ouchi Shinko Chemical Co., Ltd.)
M).・ Antiaging agent 1… 2, manufactured by Ouchi Shinko Chemical Co., Ltd.
Mercaptobenzimidazole (trade name: Nocrack M
B).・ Antiaging agent 2: Ouchi Shinko Chemical Co., Ltd., 2,
6-di-t-butyl-4-methylphenol (trade name:
Nocrack 200).

Tables 3 and 4 show the physical properties of the obtained crosslinked rubber sheet for each embodiment.

[0041]

[Table 3]

[0042]

[Table 4]

In Tables 3 and 4, details of each physical property are as follows. Strength (Kgf / cm ² ): Strength after crosslinking treatment at 160 ° C. for 20 minutes. JIS A hardness: hardness after crosslinking treatment at 160 ° C. for 20 minutes. -Weathering resistance: After the mat is prepared, the mat is folded in two with the original side of the mat inside, placed on a flat surface, and the entire upper surface of the folded mat is 10 kgf / 100.
By applying a load of ² cm ² , a distortion is given to the fold of the mat base material, and the mat base material is left in the air for 30 days, and the crack generation state near the fold of the mat base material is visually judged.

Floor contact contamination: Evaluated as follows. (1) Two 2 cm × 4 cm rubber sheet test pieces are cut from a crosslinked rubber sheet and prepared. (2) On the other hand, a flooring sample of 10 cm x 5 cm (trade name:
2 floor flume planes FL32, manufactured by Tori Corporation. (3) Two 2 cm × 4 cm rubber sheet test pieces were placed on one floor material sample, and the remaining one floor material sample was stacked thereon, and an aluminum plate (thickness Sa 1-2
mm, 8cm x 8cm), and over it, 1kg
Apply the load. This is one set. (4) Put a scale in a plastic sealed container, and place the set made in (3) on the scale. (5) Fill a sealed plastic container with water until only half of the soot is immersed. Then, the plastic sealed container is closed, and left in a 60 ° C. constant temperature bath for 7 days. (6) The degree of contact contamination of the floor material sample with the rubber sheet test piece is visually compared and scored. The score was 5: no contamination, 4: very slight cloudiness, 3: very slight contamination, 2: slightly stained, 1: strong staining.

Expansion ratio: thickness of crosslinked rubber sheet / thickness of uncrosslinked rubber sheet × 100

As is clear from Tables 3 and 4, according to the above-mentioned test for accelerating floor contamination, Embodiments 1 to 9 had a high score for floor contact contamination, and did not contaminate the floor material sample at all. Did not. In the sixth embodiment, a very slight fogging was observed at the contact portion of the floor material sample with the crosslinked rubber sheet test piece, but the fogging could be wiped off with a cloth containing a small amount of moisture. On the other hand, in Comparative Examples 1 to 3, contamination of the floor material sample was observed. In addition, Embodiments 1 to 9 had no weather resistance deterioration, that is, good weather resistance, even though the antioxidant was not added to the rubber compound. Comparative forms 1-3
Was poor in weather resistance, and Comparative Examples 1 and 2 were poor in weather resistance in spite of using an antioxidant. Further, in Embodiment 8, the crosslinked rubber sheet was a foam, but the floor contact stainability and the weather resistance were not different from those of the other embodiments. In the fourth embodiment, E is used as the rubber component.
Although a mixture of PDM and IR was used, the floor contact stainability and weathering resistance were not different from the other embodiments.

This is because the rubber components of Comparative Examples 1 to 3 are NBR, whereas the rubber components of Embodiments 1 to 9 are EPDM, EPM, or a mixture of EPDM and IR. it seems to do. That is, in the first to ninth embodiments, the EPDM, the EPM, or the EPDM
Since no mixture of the antioxidant and the crosslinking accelerator is used and the antioxidant and the crosslinking accelerator are not used, the floor contamination due to the leaching of the antioxidant and the crosslinking accelerator does not occur. In addition, EPDM or EPM itself has good weather resistance, so that the weather resistance of the mat base material can be favorably maintained without adding an antioxidant.

[0048]

According to the invention of claim 1, the weather resistance of the mat base material can be maintained well without blending an anti-aging agent which causes floor contamination. Floor contamination can be prevented.

According to the second aspect of the present invention, it is possible to prevent floor contamination due to leaching of the antioxidant.

According to the third aspect of the present invention, since a good crosslinking speed can be maintained without adding a crosslinking accelerator which may cause floor contamination, the floor is contaminated by leaching of the crosslinking accelerator. Can be prevented.

According to the fourth aspect of the present invention, the properties such as the strength, tear strength, and abrasion resistance of the mat substrate can be improved by increasing the crosslinking density.

According to the fifth aspect of the present invention, a mat substrate having good weather resistance can be obtained without adding an anti-aging agent which causes floor contamination.

According to the sixth aspect of the invention, it is possible to prevent floor contamination from occurring due to leaching of the antioxidant.

According to the seventh aspect of the present invention, a good crosslinking rate can be maintained without adding a crosslinking accelerator which may cause contamination of the floor.

According to the invention of claim 8, the crosslink density can be improved.

Claims (8)

[Claims] 1. A mat in which a mat base material is bonded to a back surface of a raw mat and the mat base material is a crosslinked rubber obtained by subjecting a rubber compound to a cross-linking treatment. A mat characterized by being a thing. 2. The mat according to claim 1, wherein the rubber compound does not contain an antioxidant. 3. The mat according to claim 1, wherein the crosslinking treatment is performed by peroxide crosslinking. 4. The mat according to claim 3, wherein the crosslinking treatment is carried out by blending a co-crosslinking agent. 5. A method for producing a mat, wherein a mat base material is bonded to the back surface of the mat raw material, and the mat base material is a crosslinked rubber obtained by cross-linking a rubber compound. Having a step of crosslinking the rubber compound in a state where the uncrosslinked sheet of the rubber compound is in contact with the back surface,
A method for producing a mat, wherein an ethylene-propylene rubber compound is used as the rubber compound in the step. 6. The method for producing a mat according to claim 5, wherein the rubber compound does not contain an anti-aging agent. 7. The method for producing a mat according to claim 5, wherein the crosslinking treatment is performed by peroxide crosslinking. 8. The method for producing a mat according to claim 7, wherein the crosslinking treatment is carried out by blending a co-crosslinking agent.