JP2002282117A - Mat, method for manufacturing it and method for recycling it - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a mat the substrate of which can easily be recycled by cleanly separating a mat fabric from the mat substrate. SOLUTION: In the mat obtained by joining the mat fabric 2 onto the mat ground fabric, the ground fabric 3 is the integrated matter of double layer structure consisting of an upper layer 31 made of first thermoplastic resin and the lower layer 32 made of second thermoplastic resin, and the softening temperature of the first thermoplastic resin is lower than that of the second thermoplastic resin.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a mat capable of recycling a mat substrate, a method for producing the mat, and a method for recycling the mat.

[0002]

2. Description of the Related Art In a mat in which a raw mat is bonded on a mat substrate, in order to recycle the mat substrate, a part of a base fabric or a pile constituting the raw mat is formed by a mat substrate. It is necessary to peel off the raw mat from the mat substrate so that it does not remain on the side. However, in the conventional mat, it has been difficult to cleanly remove the raw mat from the mat base material. Therefore, it has been difficult for conventional mats to recycle the mat base material without hindrance.

The present invention provides a mat capable of neatly peeling a mat substrate from a mat substrate, whereby the mat substrate can be satisfactorily recycled, and a method for producing such a mat. To provide,
Another object of the present invention is to provide a method for recycling such a mat.

[0004]

According to the first aspect of the present invention,
In a mat in which an original mat is bonded on a mat substrate, the mat substrate has a two-layer structure of an upper layer made of a first thermoplastic resin and a lower layer made of a second thermoplastic resin. The first thermoplastic resin is characterized in that the softening temperature of the first thermoplastic resin is lower than the softening temperature of the second thermoplastic resin.

According to a second aspect of the present invention, in the first aspect, the softening temperature of the first thermoplastic resin is lower by at least 20 ° C. than the softening temperature of the second thermoplastic resin.

According to a third aspect of the present invention, in the first aspect of the invention, the first thermoplastic resin and the second thermoplastic resin are of the same type.

According to a fourth aspect of the present invention, there is provided a method of manufacturing a mat in which a raw mat is bonded on a mat base material, wherein the raw mat, a layer made of a first thermoplastic resin, Forming a superimposed body by superimposing a layer made of a thermoplastic resin on the first thermoplastic resin so as to interpose a layer made of the first thermoplastic resin therebetween. A bonding step of joining and integrating each other by hardening after being made, and in the superimposing step, the first thermoplastic resin has a softening temperature lower than the softening temperature of the second thermoplastic resin. It is characterized by using a thing.

According to a fifth aspect of the present invention, there is provided a method for producing a mat in which a raw mat is bonded to a mat base material, wherein the raw mat and a layer made of a first thermoplastic resin in a molten state are provided. And a layer made of a second thermoplastic resin,
Producing a superimposed body by laminating a layer made of a thermoplastic resin in between, the superimposing step, and the superimposed body are bonded to each other and integrated by curing the first thermoplastic resin, And a bonding step, wherein in the overlapping step, a first thermoplastic resin having a softening temperature lower than a softening temperature of the second thermoplastic resin is used.

According to a sixth aspect of the present invention, there is provided a method of manufacturing a mat in which a raw mat is bonded on a mat base material, wherein the raw mat is bonded on a layer made of a first thermoplastic resin. Stacking the laminated body formed on the layer made of the second thermoplastic resin to form an overlapped body, and curing the overlapped body after at least melting the first thermoplastic resin. And a joining step of joining and integrating each other with each other, wherein in the overlapping step, a first thermoplastic resin having a softening temperature lower than the softening temperature of the second thermoplastic resin is used. And

According to a seventh aspect of the present invention, there is provided a method for manufacturing a mat in which an original mat is bonded on a mat base material, wherein the mat comprises a layer made of a first thermoplastic resin and a second thermoplastic resin. Using a layer continuous in the longitudinal direction as a layer, the first layer made of the thermoplastic resin is moved in the longitudinal direction, and the first layer is sequentially placed on the layer made of the second thermoplastic resin in the moving direction. The operation of superimposing a layer made of a thermoplastic resin and the operation of further laminating a mat raw material thereon, and performing each operation in succession, thereby producing a superimposed body, a superimposing step, and a superimposed body A bonding step in which the first thermoplastic resin is cured after being melted at least, thereby bonding and integrating the first thermoplastic resin with each other, and in the overlapping step, the second thermoplastic resin is used as the first thermoplastic resin. Thermoplastic tree It is characterized by the use of one of lower softening temperature than the softening temperature of the.

According to an eighth aspect of the present invention, there is provided a method for manufacturing a mat in which an original mat is bonded on a mat base material, wherein the mat comprises a layer made of a first thermoplastic resin and a second thermoplastic resin. A layer that is continuous in the longitudinal direction is used as the layer, and a layer that is in a molten state is used as the layer that is made of the first thermoplastic resin, and the moving direction is made while moving the layer that is made of the second thermoplastic resin in the longitudinal direction. In the order, the work of stacking the layer made of the first thermoplastic resin on the layer made of the second thermoplastic resin and the work of stacking the matte material on the layer are performed successively. Then do
Accordingly, a superimposing step of producing a superimposed body, and a joining step of joining and integrating the superimposed body with each other by curing the first thermoplastic resin are provided. As the first thermoplastic resin, one having a softening temperature lower than the softening temperature of the second thermoplastic resin is used.

[0012] According to a ninth aspect of the present invention, in the invention of the seventh or eighth aspect, in the superimposing step, a continuous mat in the longitudinal direction is used as the mat raw material.

According to a tenth aspect of the present invention, there is provided a method of manufacturing a mat in which a raw mat is bonded to a mat base material, wherein the raw mat, a layer made of a first thermoplastic resin,
And a layer made of the second thermoplastic resin, which is continuous in the longitudinal direction, and while moving the matte raw material in the longitudinal direction, the first material is sequentially placed on the back surface of the matte raw material along the moving direction. Work of laminating layers of thermoplastic resin,
Further, the operation of superimposing a layer made of the second thermoplastic resin thereon is performed, and the respective operations are continuously performed, thereby forming a superimposed body. A joining step of joining and integrating the thermoplastic resins by melting and then hardening the thermoplastic resins, and in the overlapping step, the softening temperature of the second thermoplastic resin as the first thermoplastic resin. It is characterized by using a material having a lower softening temperature.

According to an eleventh aspect of the present invention, there is provided a method for manufacturing a mat in which a raw mat is bonded onto a mat base material, wherein the raw mat, a layer made of a first thermoplastic resin,
And, as a layer made of the second thermoplastic resin, a layer continuous in the longitudinal direction is used, and a layer made of the first thermoplastic resin is used in a molten state, while moving the raw mat in the longitudinal direction. An operation of superposing a layer made of the first thermoplastic resin on the back surface of the raw mat and an operation of superposing a layer made of the second thermoplastic resin thereon are further performed in this order along the moving direction. At the same time, each operation is continuously performed, thereby producing a superimposed body, the superimposing step, and the superimposed body is cured by curing the first thermoplastic resin.
And a joining step of joining and integrating each other,
In the superimposing step, the first thermoplastic resin has a softening temperature lower than the softening temperature of the second thermoplastic resin.

According to a twelfth aspect of the present invention, in the method for producing a mat in which a raw mat is bonded on a mat base material, a layer continuous in the longitudinal direction is used as a layer made of a second thermoplastic resin. While moving the layer made of the second thermoplastic resin in the longitudinal direction, the laminate formed by joining the raw mat to the layer made of the first thermoplastic resin is continuously stacked thereon. Producing a superimposed body, a superimposing step,
The superimposed body is cured after at least the first thermoplastic resin is melted, so that the superimposed body is joined to and integrated with each other, and in the superimposing step, the first thermoplastic resin is used as a first thermoplastic resin. The second resin is characterized by using a resin having a softening temperature lower than the softening temperature of the thermoplastic resin.

According to a thirteenth aspect of the present invention, in the invention of any one of the fourth to twelfth aspects, in the joining step, the second thermoplastic resin is also melted and then cured.

According to a fourteenth aspect of the present invention, in the invention according to any one of the fourth to twelfth aspects, in the overlapping step, a layer made of the second thermoplastic resin is used in a molten state. The second thermoplastic resin is also cured.

According to a fifteenth aspect of the present invention, there is provided a mat in which an original mat is bonded to a mat base material, wherein the mat base material is provided with an upper layer made of a first thermoplastic resin and a second thermosetting resin. A two-layer structure with a lower layer made of a plastic resin,
A method for recycling a mat base material in a mat in which a softening temperature of a first thermoplastic resin is lower than a softening temperature of a second thermoplastic resin, wherein the mat is higher than a softening temperature of the first thermoplastic resin. And, by heating to a temperature lower than the softening temperature of the second thermoplastic resin, the layer made of the first thermoplastic resin is softened, and in that state, the mat substrate is peeled off from the mat raw material, and a separation step is performed. It is characterized by having.

[0019]

(Embodiment 1) FIG. 1 is a longitudinal sectional view of a mat of the present invention. This mat 1 is a mat mat 2
Are joined on the mat base material 3.

The mat base material 3 comprises an upper layer 31 made of a first thermoplastic resin and a lower layer 3 made of a second thermoplastic resin.
2 with a two-layer structure. As the first thermoplastic resin, one having a softening temperature lower than the softening temperature of the second thermoplastic resin is used. Specifically, as the first thermoplastic resin, trade name “Kuramicron U 918”
0 (manufactured by Kuraray Co., Ltd.), and as the second thermoplastic resin, trade name “Kuramicron U 9190”
(Made by Kuraray Co., Ltd.). In the former, the melting point was measured at a heating rate of 10 ° C./min using a DSC, but the melting point was about 120 ° C.
° C. In the latter, also the melting point is about 164 ° C and the Piccat softening temperature is 95 ° C. In addition, mat 1
In, the thickness of the layer 31 is 0.5 mm, and the thickness of the layer 32 is 0.8 mm.

The raw mat 2 is configured by tufting a pile 21 on a base cloth 22. And the matte web 2
Are bonded on the mat substrate 3 so that the pile 21 is embedded in the layer 31 of the mat substrate 3.

The mat 1 having the above structure is manufactured through the following superimposing step and joining step. In the superimposing step, as shown in FIG. 2, the matte raw material 2, the layer 31, and the layer 32 are superimposed in this order from above to produce a superimposed body 4 shown in FIG. In the joining step, the superimposed body 4 is joined to each other and integrated by curing the layer 31 after the layer 31 is melted. The melting of the layer 31 is performed by heating the superimposed body 4 from below or above. The hardening of the layer 31 is performed by leaving it to stand, but may be actively cooled.

In the above-described manufacturing method, since the layer 31 is melted, the layer 31 adheres to the mat substrate 2 and the layer 32, respectively, and the layer 31 is hardened. Joining, and therefore the superimposing bodies 4 join together and become integral. Therefore, the mat 1 of FIG. 1 is obtained.

The mat 1 having the above structure was subjected to a washing fatigue test. [Washing fatigue test] A mat sample was washed with a laundry capacity of 30.
It is put into a large Kg washing machine, washed in warm water of 50 ° C. for 15 minutes, dehydrated, and dried in a dryer at a temperature of 60 ° C. After repeating this 20 times, the state of the mat sample is observed. The amount of the mat sample introduced into the large washing machine is adjusted to be about 30 kg. [Test Results] The mat 1 had sufficient durability.

Next, the mat substrate 3 of the mat 1 having the above structure
Tried recycling. First, separation of the mat substrate 2 and the mat substrate 3 was attempted. That is, the mat 1 is heated to 80 ° C., which is higher than the softening temperature of the first thermoplastic resin and lower than the softening temperature of the second thermoplastic resin.
1 was softened, and in this state, the end of the raw mat 2 was gripped with pliers and peeled from the mat substrate 3 as shown in FIG. As a result, the first thermoplastic resin adheres to the peeled mat substrate 2, but most of the layer 31 remains bonded to the layer 32, and the layer 31 bonded to the layer 32.
The pile 21 and the base fabric 22 of the original mat 2 are not attached at all to the portion. That is, most of the mat substrate 3 is separated from the mat substrate 2 without including the pile 21 and the base fabric 22 of the mat substrate 2 at all.

In particular, in the mat 1, the difference between the softening temperature of the first thermoplastic resin and the softening temperature of the second thermoplastic resin is 2
Since the temperature is 0 ° C. or higher, only the layer 31 can be sufficiently softened, and therefore, the separation of the raw mat 2 from the mat substrate 3 can be performed satisfactorily.

Then, using the separated mat substrate 3, an attempt was made to produce a new mat substrate. That is,
The layer 31 and the layer 32, which are the separated mat substrates 3, were heated and kneaded, and then formed into a sheet. This sheet was used as a mat substrate for a new mat. The softening temperature of this sheet was 90 ° C. Therefore, this sheet
The material was hardly different from the layer 32, and there was no problem in using it as a mat base material for a new mat. In particular, in the mat 1, since the layers 31 and 32 are made of the same type of thermoplastic resin, the layers 31 and 3
2 obtained by heating and kneading no significant change in material properties.

In the mat of the present invention, the following modified structure may be adopted. That is, the mat 1 in FIG. 1 does not have the ear portion, that is, the portion of the mat base material 3 that protrudes around the mat substrate 2 in a plan view. Also, the present invention can be applied to a mat having ears as shown in FIG. In the mat of FIG.
Is composed of a layer 31 and a layer 32. In the mat of FIG. 6, the ear 33 is composed of only the layer 32.

In the method of manufacturing a mat according to the present invention, the following deformation method may be employed. (1) In the bonding step, the layer 32 is also cured after being melted. According to this, the bonding between the layer 31 and the layer 32 is favorably performed. (2) In the superimposing step, the layer 32 in a molten state is used, and in the bonding step, the layer 32 is also cured. According to this,
The bonding between the layer 31 and the layer 32 is favorably performed. The layer 32 in the molten state is formed by a T-die. (3) In the superimposing step, the mat material 2, the layer 31,
The layer 32 and the layer 32 are superimposed in this order from below to produce a superimposed body 4.

(Embodiment 2) The mat of the present invention can also be manufactured by a method including the following superimposing step and joining step. In the superimposing step, the raw mat 2 and the layer 3 in the molten state
1 and the layer 32 are overlapped so as to sandwich the layer 31 therebetween, thereby producing a superimposed body 4. The layer 31 in the molten state is formed by a T-die. In the joining step, the superimposed body 4 is joined to each other and integrated by curing the layer 31.

According to this method, since the joining step only requires leaving the superimposed body 4 alone, the joining operation becomes extremely easy. The other effects are the same as those of the first embodiment.

In this method, the same deformation method as in the first embodiment can be adopted.

(Embodiment 3) The mat of the present invention can also be manufactured by a method including the following superimposing step and joining step. In the superimposing step, as shown in FIG. 7, a laminated body 5 in which the raw mat 2 is bonded on the layer 31 is first prepared, and the laminated body 5 is superimposed on the layer 32, and the superimposed body 4 is formed. Make it. In addition, the laminated body 5 is produced by melting and hardening the layer 31 in a state where the raw mat 2 and the layer 31 are overlapped. In the joining step, the superimposed body 4 is joined to each other and integrated by curing the layer 31 after melting the layer 31.

According to this method, the operation of directly manufacturing the superimposed body 4 is facilitated. The other effects are the same as those of the first embodiment.

In this method, the same deformation method as in the first embodiment can be adopted.

(Embodiment 4) The mat of the present invention can be manufactured continuously by the following methods 1 to 5.

[Method 1] FIG. 8 is a sectional view showing the operation of the present method. This method goes through the following superimposing step and joining step. In the superimposing step, layers 31 and 32 that are continuous in the longitudinal direction are used, and while the layer 32 is moved in the longitudinal direction, the layers 31 and 32 are sequentially placed on the layer 32 in the moving direction.
Is performed, and further, the operation of superimposing the matte web 2 thereon is performed, and each operation is continuously performed, whereby the superimposed body 4 is manufactured. In addition, what is cut into a predetermined dimension is used as the raw mat 2. The layers 31 and 32 are supplied from, for example, a roll. Also,
The movement of the layer 32 is performed, for example, by placing it on an endless annular drive belt. In the joining step, the superimposed body 4 is joined to each other and integrated by curing the layer 31 after melting the layer 31. The melting of the layer 31 is performed by heating the superimposed body 4 from below or above. The hardening of the layer 31 is performed by leaving it unattended, but may be actively cooled. Then, as shown by a dashed line A in FIG. 8, the mat base material 3 composed of the layer 31 and the layer 32 is cut along the periphery of the raw mat 2 and at a little distance from the periphery. Thereby, the mat shown in FIG. 5 having the ears 33 is continuously obtained.

Also in this method, since the layer 31 is cured after being melted, bonding is performed after the layer 31 is adhered to the mat substrate 2, and bonding is performed after the layer 31 is adhered to the layer 32. The bodies 4 are joined together and integrated.

The following deformation method may be employed. (1) In the superimposing step, as shown in FIG. 9, a continuous mat material 2 is used in the longitudinal direction. According to this, the work of stacking the matte web 2 on the layer 31 is simplified, and the workability is improved. However, in this method, as shown by a dashed line A in FIG.
And the mat substrate 3 are cut together, so that there is no
Are continuously obtained. The raw mat 2 is supplied, for example, from a roll. (2) The mat substrate 3 is cut along the periphery of the mat substrate 2. According to this, the mat 1 shown in FIG. 1 without ears is obtained.

[Method 2] This method includes the following superimposing step and joining step. In the superimposing step, layers 31 and 32 that are continuous in the longitudinal direction are used, and a layer 31 that is in a molten state is used. The layers 32 are sequentially moved along the moving direction while moving the layers 32 in the longitudinal direction. The work of superimposing the layer 31 on the work 32 and the work of superimposing the raw mat 2 thereon are performed, and each work is continuously performed, whereby the superimposed body 4 is manufactured. The layer 31 in the molten state is formed by a T-die. In the joining step, the superimposed body 4 is joined to each other and integrated by curing the layer 31. And
Cutting is performed in the same manner as in Method 1.

The present method is characterized in that the layer 31 in a molten state is used in the superposition step as compared with the method 1. According to this method, since the joining step only needs to leave the superimposed body 4, the joining operation becomes extremely easy.

Note that the same deformation method as in method 1 may be employed.

[Method 3] FIG. 10 is a sectional view showing the operation of this method. This method goes through the following superimposing step and joining step. In the superimposing step, the raw mat 2, the layer 31, and the layer 3
2, a material that is continuous in the longitudinal direction is used, and while moving the raw material mat 2 in the longitudinal direction, an operation of layering the layer 31 on the back surface of the raw mat material 2 sequentially along the moving direction, and furthermore, The operation of superimposing the layer 32 thereon is performed, and each operation is continuously performed, whereby the superimposed body 4 is manufactured. The movement of the mat web 2 is performed, for example, by placing the mat web 2 on an endless annular drive belt. The superimposed body 4 is bonded to each other and integrated by hardening after the layer 31 is melted. And FIG.
As shown by the alternate long and short dash line A in FIG. 0, the raw mat sheet 2 and the mat base material 3 are cut. Thereby, the mat 1 shown in FIG. 1 without the ears is continuously obtained.

The present method is characterized in that the raw mat 2 is the lowermost layer. In this method, the operation of superimposing the mat raw material 2 continuous in the longitudinal direction on the layer 31 is performed by using the mat raw material 2 used.
This is meaningful because it is possible to eliminate the work when it is difficult due to the type or the like.

[Method 4] The present method includes the following superimposing step and joining step. In the superimposing step, the raw mat 2, the layer 31, and the layer 3
As layer 2, a layer continuous in the longitudinal direction is used, and layer 3
1. Using a molten material as 1 and moving the raw material mat 2 in the longitudinal direction, successively along the moving direction, stacking the layer 31 on the back surface of the raw mat 2, and In addition to performing the operation of superimposing 32, each operation is continuously performed, thereby producing the superimposed body 4. In the joining step, the superimposed body 4 is joined to each other and integrated by curing the layer 31. And
Cutting is performed in the same manner as in Method 3.

The present method is characterized in that the layer 31 in a molten state is used in the superposition step as compared with the method 3. According to this method, since the joining step only needs to leave the superimposed body 4, the joining operation becomes extremely easy.

[Method 5] FIG. 11 is a sectional view showing the operation of the present method. This method goes through the following superimposing step and joining step. In the superimposing step, a layer 32 continuous in the longitudinal direction is used, and the layer 32 is moved in the longitudinal direction.
The laminated body 5 formed by bonding the matte raw material 2 to the base material 1 is continuously laminated thereon to produce the superimposed body 4. Note that the laminate 5 has ears 33. In the joining step, the superimposed body 4 is joined to each other and integrated by curing the layer 31 after melting the layer 31. Then, the layer 32 is cut along the periphery of the layer 31 as shown by a dashed line A in FIG. This allows
The mat shown in FIG. 5 having the ears 33 is continuously obtained.

The present method is characterized in that the laminate 5 is prepared first. According to this method, the operation of directly manufacturing the superimposed body 4 is facilitated.

The following deformation method may be adopted. That is, the mat base material 3 is cut along the periphery of the mat raw material 2. According to this, the mat 1 shown in FIG. 1 without ears is obtained.

In the methods 1 to 5, the following modification may be adopted. (1) In the bonding step, the layer 32 is also cured after being melted. According to this, the bonding between the layer 31 and the layer 32 is favorably performed. (2) In the superimposing step, the layer 32 in a molten state is used, and in the bonding step, the layer 32 is also cured. According to this,
Not only is the bonding between the layers 31 and 32 good,
Since the joining process only needs to leave the superimposed body 4 alone, the joining operation becomes extremely easy.

[0051]

According to the first aspect of the present invention, the upper layer made of the first thermoplastic resin is softened, and in this state, the raw mat is peeled off from the mat base material. The mat base material to which the base cloth and the pile are not adhered can be obtained by separating the mat base material. Therefore, the mat substrate obtained by separation can be favorably recycled as a mat substrate of a new mat.

According to the second aspect of the present invention, only the upper layer made of the first thermoplastic resin can be sufficiently softened, so that the separation operation can be performed well.

According to the third aspect of the present invention, there is no significant change in the material even when the mat base material obtained by separation is heated and kneaded, so that the mat base material of a new mat or the resin of another product can be used. It can be recycled well as a material. When a change in material properties becomes a problem, the modification may be performed by mixing an appropriate resin or an additive.

According to the fourth aspect of the present invention, in the joining step, the first thermoplastic resin is melted, so that the layer made of the first thermoplastic resin is separated from the raw matte and the second thermoplastic resin. The first thermoplastic resin adheres to the respective layers, and the first thermoplastic resin is cured, so that the layers composed of the first thermoplastic resin are respectively bonded to both. Therefore, the mat according to claim 1 can be obtained.

According to the fifth aspect of the present invention, in the superimposing step, the layer made of the first thermoplastic resin in a molten state adheres to the original mat and the layer made of the second thermoplastic resin, respectively, and the joining step is performed. In the above, when the first thermoplastic resin is cured, the layer made of the first thermoplastic resin is bonded to both. Therefore, the mat according to claim 1 can be obtained.

According to the sixth aspect of the invention, in the joining step, the first thermoplastic resin is melted, so that the layer made of the first thermoplastic resin is separated from the raw matte and the second thermoplastic resin. The first thermoplastic resin adheres to the respective layers, and the first thermoplastic resin is cured, so that the layers composed of the first thermoplastic resin are respectively bonded to both. Therefore, the mat according to claim 1 can be obtained. In addition, since the laminate is used in the superimposing step, the superimposed body can be easily manufactured,
The workability of the superposition step can be improved.

According to the seventh aspect of the present invention, in the joining step, the first thermoplastic resin is melted, so that the layer made of the first thermoplastic resin is separated from the raw material mat and the second thermoplastic resin. The first thermoplastic resin adheres to the respective layers, and the first thermoplastic resin is cured, so that the layers composed of the first thermoplastic resin are respectively bonded to both. Therefore, the mat according to claim 1 can be obtained. In addition, since the superimposed body can be continuously produced in the superimposing step, the mat according to claim 1 can be continuously obtained.

According to the eighth aspect of the invention, in the superimposing step, the layer made of the first thermoplastic resin in a molten state adheres to the raw material mat and the layer made of the second thermoplastic resin, respectively. In the above, when the first thermoplastic resin is cured, the layer made of the first thermoplastic resin is bonded to both. Therefore, the mat according to claim 1 can be obtained. In addition, since the superimposed body can be continuously produced in the superimposing step, the mat according to claim 1 can be continuously obtained.

According to the ninth aspect of the present invention, in the superimposing step, the operation of superimposing the raw mat on the layer made of the first thermoplastic resin can be simplified, and the workability can be improved.

According to the tenth aspect, in the joining step, the first thermoplastic resin is melted,
The layer made of the first thermoplastic resin adheres to the raw mat and the layer made of the second thermoplastic resin, respectively, and the first thermoplastic resin is cured, whereby the layer made of the first thermoplastic resin is formed. Join to both. Therefore, claim 1
The mat described can be obtained. In addition, since the superimposed body can be continuously produced in the superimposing step, the mat according to claim 1 can be continuously obtained. Further, in the superimposing step, since the original mat is the lowermost layer, it is possible to prevent the case where it is troublesome to overlap the original mat from above due to the type of the original mat.

According to the eleventh aspect of the present invention, in the superimposing step, the layer made of the first thermoplastic resin in a molten state adheres to the raw material mat and the layer made of the second thermoplastic resin, respectively. In the above, when the first thermoplastic resin is cured, the layer made of the first thermoplastic resin is bonded to both. Therefore, the mat according to claim 1 can be obtained. In addition, since the superimposed body can be continuously produced in the superimposing step, the mat according to claim 1 can be continuously obtained. Further, in the superimposing step,
Since the original mat is the lowermost layer, it is possible to prevent the case where it is difficult to overlap the original mat from above due to the type of the original mat.

According to the twelfth aspect of the invention, in the joining step, the first thermoplastic resin is melted,
The layer made of the first thermoplastic resin adheres to the raw mat and the layer made of the second thermoplastic resin, respectively, and the first thermoplastic resin is cured, whereby the layer made of the first thermoplastic resin is formed. Join to both. Therefore, claim 1
The mat described can be obtained. In addition, since the superimposed body can be continuously produced in the superimposing step, the mat according to claim 1 can be continuously obtained. Furthermore, since the laminated body is used in the superimposing step, the superimposed body can be easily manufactured, and the workability of the superimposing step can be improved.

According to the thirteenth aspect of the present invention, in the joining step, adhesion and joining between the layer made of the first thermoplastic resin and the layer made of the second thermoplastic resin can be favorably performed.

According to the fourteenth aspect of the present invention, in the overlapping step, the layer made of the first thermoplastic resin and the layer made of the second thermoplastic resin can be satisfactorily adhered to each other. In the above, both can be satisfactorily joined.

According to the fifteenth aspect of the present invention, since the first thermoplastic resin is softened, the raw mat can be easily peeled off from the layer made of the first thermoplastic resin, and the raw mat can be removed. The mat substrate to which the base cloth or the pile is not adhered can be obtained by separating the mat substrate from the mat substrate. Therefore, the mat substrate obtained by separation can be favorably recycled as a mat substrate of a new mat.

[Brief description of the drawings]

FIG. 1 is a longitudinal sectional view of a mat of the present invention.

FIG. 2 is a longitudinal sectional view showing one step of the method for producing a mat of the present invention.

FIG. 3 is a longitudinal sectional view of a superimposed body obtained in a step following FIG. 2;

FIG. 4 is a longitudinal sectional view showing an operation state of the recycling method of the present invention.

FIG. 5 is a longitudinal sectional view of another example of the mat of the present invention.

FIG. 6 is a longitudinal sectional view of a mat according to still another example of the present invention.

FIG. 7 is a longitudinal sectional view showing one step of another method for manufacturing a mat of the present invention.

FIG. 8 is a longitudinal sectional view showing the operation of still another method of manufacturing the mat of the present invention.

FIG. 9 is a longitudinal sectional view showing the operation of still another method of manufacturing the mat of the present invention.

FIG. 10 is a longitudinal sectional view showing the operation of still another method of manufacturing the mat of the present invention.

FIG. 11 is a longitudinal sectional view showing the operation of still another method of manufacturing the mat of the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Mat 2 Mat raw material 3 Mat base material 31, 32 layers 4 Superimposed body 5 Laminated body

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI Theme coat ゛ (Reference) B29K 105: 08 B29K 105: 08 B29L 9:00 B29L 9:00 F term (Reference) 3B120 CA08 DB01 EB30 4F100 AK01A AK01B AT00A AT00B BA02 BA03 BA07 BA26 DG06C DG16C EC03 EC032 JA04A JA04B JB16A JB16B JL16 YY00A YY00B 4F211 AC01 AD16 AG03 TA01 TC04 TD11 TH02 TH06 TN56 TQ01 TQ10 TW06 TW15 TW45 4F301

Claims (15)

[Claims] 1. A mat in which a raw mat is bonded to a mat substrate, wherein the mat substrate comprises an upper layer made of a first thermoplastic resin and a lower layer made of a second thermoplastic resin. A mat having a two-layer structure, wherein the softening temperature of the first thermoplastic resin is lower than the softening temperature of the second thermoplastic resin. 2. The softening temperature of the first thermoplastic resin is at least 20 ° C. lower than the softening temperature of the second thermoplastic resin.
Matt described. 3. The mat according to claim 1, wherein the first thermoplastic resin and the second thermoplastic resin are the same type of resin. 4. A method for producing a mat in which a raw mat is bonded onto a mat substrate, comprising: a raw mat; a layer made of a first thermoplastic resin;
A layer made of a thermoplastic resin is overlapped so as to sandwich a layer made of the first thermoplastic resin therebetween, thereby producing a superposed body.
A superimposing step; and a joining step, in which the superimposed body is cured by melting at least the first thermoplastic resin, thereby joining and integrating each other. A method for producing a mat, wherein a resin having a softening temperature lower than the softening temperature of the second thermoplastic resin is used as the resin. 5. A method for producing a mat in which a raw mat is bonded on a mat substrate, comprising: a raw mat, a layer made of a first thermoplastic resin in a molten state, and a second thermoplastic resin. A superimposing step of forming a superimposed body by superposing a layer made of a resin and a layer made of a first thermoplastic resin between the layers, by curing the first thermoplastic resin, And a joining step of joining and integrating each other. In the overlapping step, a first thermoplastic resin having a softening temperature lower than a softening temperature of the second thermoplastic resin is used. Mat production method. 6. A method for producing a mat in which a raw mat is bonded onto a mat base material, comprising: forming a laminate in which the raw mat is bonded on a layer made of a first thermoplastic resin; Superimposing on the layer made of the second thermoplastic resin to form a superimposed body; and bonding the superimposed body to each other by hardening at least after melting the first thermoplastic resin. And a joining step, wherein the first thermoplastic resin having a softening temperature lower than the softening temperature of the second thermoplastic resin is used in the superimposing step. . 7. A method for producing a mat in which a raw mat is bonded onto a mat base material, comprising: a first thermoplastic resin layer and a second thermoplastic resin layer which are continuous in a longitudinal direction. Using the second
While moving the layer made of the thermoplastic resin in the longitudinal direction, sequentially along the moving direction, the operation of stacking the layer made of the first thermoplastic resin on the layer made of the second thermoplastic resin, and While performing the operation | work which lays a mat | matte raw material on it and performing each operation | work continuously, the superimposing process which produces | generates a superimposed body by this, the superimposed body melt | melted at least 1st thermoplastic resin. And a joining step of joining and integrating them by hardening later. In the overlapping step, a first thermoplastic resin having a softening temperature lower than the softening temperature of the second thermoplastic resin is used. A method for producing a mat, which is used. 8. A method for producing a mat in which an original mat is bonded to a mat substrate, comprising: a first thermoplastic resin layer and a second thermoplastic resin layer which are continuous in a longitudinal direction. The first thermoplastic resin layer is used in a molten state, and while the second thermoplastic resin layer is moved in the longitudinal direction, the first thermoplastic resin layer is sequentially moved along the moving direction. In addition to performing the operation of layering the first thermoplastic resin layer on the layer of the second thermoplastic resin and the operation of further laminating the mat raw material thereon, the respective operations are continuously performed. Producing a superimposed body; and a joining step of joining the superimposed bodies together by curing the first thermoplastic resin to thereby integrate the superimposed bodies. As a thermoplastic resin A method of using a mat having a softening temperature lower than the softening temperature of the second thermoplastic resin. 9. The method according to claim 7, wherein, in the superimposing step, a continuous mat is used in the longitudinal direction also as a raw mat.
Or the method for producing a mat according to 8. 10. A method for producing a mat in which a raw mat is bonded onto a mat substrate, comprising: a raw mat; a layer made of a first thermoplastic resin;
As a layer made of a thermoplastic resin, using a continuous material in the longitudinal direction, while moving the matte raw material in the longitudinal direction,
In the order along the moving direction, an operation of laminating a layer made of the first thermoplastic resin on the back surface of the raw mat and an operation of laminating a layer made of the second thermoplastic resin thereon are further performed. Performing each operation in succession, thereby forming a superimposed body, and a superimposing step. The superimposed body is bonded and integrated by at least melting the first thermoplastic resin and then curing the same. And a bonding step. In the superimposing step, a mat having a softening temperature lower than a softening temperature of the second thermoplastic resin is used as the first thermoplastic resin. 11. A method for producing a mat in which a raw mat is bonded to a mat substrate, comprising: a raw mat; a layer made of a first thermoplastic resin;
As a layer made of the thermoplastic resin, a layer continuous in the longitudinal direction is used, and a layer made of the first thermoplastic resin is used in a molten state. In order along the direction, the operation of stacking a layer made of the first thermoplastic resin on the back surface of the raw mat and the operation of stacking a layer made of the second thermoplastic resin thereon are further performed. The operations are continuously performed, thereby forming a superimposed body, a superimposing step, and the superimposing body are bonded to each other and integrated by curing the first thermoplastic resin. A method for producing a mat, wherein in the superposing step, a first thermoplastic resin having a softening temperature lower than a softening temperature of a second thermoplastic resin is used. 12. A method for producing a mat in which an original mat is bonded on a mat base material, wherein a layer made of a second thermoplastic resin that is continuous in the longitudinal direction is used. While moving the resin layer in the longitudinal direction, a laminate formed by joining the raw mat to the layer made of the first thermoplastic resin is continuously laminated thereon to produce a laminate. A superimposing step; and a joining step in which the superimposed body is cured by melting at least the first thermoplastic resin so as to be joined and integrated with each other. A method for producing a mat, comprising using a thermoplastic resin having a softening temperature lower than the softening temperature of the second thermoplastic resin. 13. The method according to claim 4, wherein in the joining step, the second thermoplastic resin is also melted and then cured. 14. In the superimposing step, a layer made of a second thermoplastic resin is used in a molten state, and in the joining step, the second thermoplastic resin is also cured.
A method for producing a mat according to any one of claims 4 to 12. 15. A mat formed by bonding a raw mat to a mat base material, wherein the mat base material comprises an upper layer made of a first thermoplastic resin and a lower layer made of a second thermoplastic resin. A mat having a two-layer structure with the first layer, wherein the softening temperature of the first thermoplastic resin is lower than the softening temperature of the second thermoplastic resin. Heating the layer made of the first thermoplastic resin by heating to a temperature higher than the softening temperature of the first thermoplastic resin and lower than the softening temperature of the second thermoplastic resin; A method of separating the mat from the raw material of the mat.