JP2009247754A - Sliding prevention pile mat and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a sliding prevention pile mat, which is easy to manufacture, is hard to slide on the mounting surface such as a floor, and also excels in durability, and its manufacturing method. <P>SOLUTION: A PTFE thin glass fiber fabric DL, which uniformly has many small recesses R with a depth of about 25 μm, is mounted on a lower pressurization hot press SL, an unvulcanized NBR rubber sheet B is mounted on it, a pile fabric P and unvulcanized NBR edge rubber E surrounding its surroundings are mounted on it, and furthermore a PTFE thin glass fiber fabric DH is mounted on it. By pressurization heating them by pressing between vertical pressurization hot presses SH-SL, the NRB rubber sheet and the NBR edge rubber E, which compose a mat base layer B, are converted into an elastomer by vulcanization and the mat base layer B and a pile layer P are integrated, and a sliding prevention pile mat M, in which the many small recesses R with a depth of about 25 μm are uniformly formed in the bottom of the mat base layer B, is obtained. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention is a sliding structure in which a pile layer in which a large number of piles are planted on a sheet-like substrate is laminated on an elastomer mat base layer made of a vulcanized rubber material, and sliding on a mounting surface is prevented. The present invention relates to a prevention pile mat and a manufacturing method thereof.

  Pile mats, especially pile mats for business use used for wiping shoes, etc., are laminated on a mat base layer made of vulcanized rubber material with a pile layer in which a large number of piles are planted on a sheet-like substrate. In many cases, the two are integrally formed and a large number of small concave portions are uniformly formed on the bottom surface of the mat base layer. In these pile mats, the depth of many small recesses formed on the bottom surface of the mat base layer is about 100 μm.

  Such a pile mat vulcanizes the rubber material constituting the mat base layer by heating a laminate of pile layers on an unvulcanized mat base layer while sandwiching it with a pressure surface facing in the laminating direction. It is obtained by making it an elastomer and integrating the mat base layer and the pile layer, and has a large number of small recesses with a depth of about 100 μm as the bottom surface-side pressing surface opposite to the bottom surface of the mat base layer. I used something.

  Such pile mats, especially pile mats for business use, may not be able to fulfill the function of removing mud and dust such as shoes of walking people by shifting from the predetermined placement position, walls, furniture, Some of the devices hit other devices, and some of them swell, causing a person to walk on the road, or being caught by an automatic door and causing a failure of the automatic door.

  In order to prevent displacement of a pile mat in which a pile layer in which a large number of piles are planted on a sheet-like substrate is laminated on an elastomer mat base layer made of a vulcanized rubber material, the elastomer constituting the mat base layer is prevented. The material is made of a material having a large coefficient of friction with the mounting surface, in particular, a material having adhesiveness, and the periphery of the mat base is fixed to the mounting surface with an adhesive tape.

  However, fixing with an adhesive tape requires cost and labor since it must be repeated every time the mat is replaced for cleaning. Further, when the adhesiveness of the elastomer material is increased in order to increase the coefficient of friction with the mounting surface, there is a disadvantage that it becomes difficult to remove the dirt when the mat base becomes dirty.

  Japanese Patent Application Laid-Open No. 2000-139672 (Patent Document 1) has an anti-slip layer coated with an anti-slip agent obtained by blending a hollow fine particle obtained by coating inorganic hollow fine particles or inorganic powder with an aqueous resin, and then drying. The rug is listed.

However, it is unclear whether such an anti-slip layer by coating can exhibit sufficient durability in long-term use, particularly when used for commercial mats that are repeatedly washed.
JP 2000-139672 A

  The present invention has been made in view of the above-described problems existing in the prior art, and the object of the present invention is easy to manufacture and difficult to slide on a mounting surface such as a floor surface. An object of the present invention is to provide a non-sliding pile mat having excellent durability and a method for producing the same.

  A pile mat in which a pile layer in which a large number of piles are planted on a sheet-like base material is laminated on an elastomer mat base layer made of a vulcanized rubber material is used as a mounting surface such as a floor surface. In order to make it difficult to slide above, it is conceivable to make the depth of the small concave portions uniformly formed on the bottom surface of the mat base layer small.

  However, in order to obtain such a pile mat, when a bottom surface-side pressure surface facing the bottom surface of the mat base layer is uniformly provided with a large number of small concave portions having a small depth, the bottom surface of the mat base layer is It was found that a concave wrinkle due to the gas remaining between the side pressurizing surface, in particular, a groove-shaped wrinkle tends to occur. Such concave wrinkles can cause damage to the mat or speed up its progress during processing such as washing with a centrifugal washing machine or use as a mat.

  Further, it was found that when the depth of the small concave portion is further reduced, the pile mat is easily slid on the mounting surface when water penetrates between the mat and the mounting surface.

  According to the present invention, by the means described below, an anti-skid pile mat that prevents the formation of concave wrinkles due to residual gas at the time of manufacture on the bottom surface of the mat base layer and is difficult to slide on the mounting surface as much as possible. And the manufacturing method can be provided.

The anti-skid pile mat of the present invention is
An elastomeric mat base layer made of vulcanized rubber material;
A pile layer in which a large number of piles are planted on a sheet-like substrate, the base end of the pile being located on the lower surface side of the sheet-like substrate,
A pile mat is formed by laminating a pile layer on a mat base layer, and the two are integrally formed, and a large number of small recesses are uniformly formed on the bottom surface of the mat base layer,
The depth of the small concave portion is 5 to 50 μm.

  In this anti-skid pile mat, the depth of the small recesses uniformly formed on the bottom surface of the mat base layer is 5 to 50 μm. It is desirable that the depth of the small recess is substantially constant at the bottom surface of the mat base layer. However, the depth of the small recesses on the bottom surface of the mat base layer is not necessarily required to be constant. Preferably, the depth of the small recess is 10 to 45 μm.

  This pile mat is relatively difficult to slide on a mounting surface such as a floor surface as compared with a conventional pile mat having a small concave portion having a depth of about 100 μm. Further, even when water permeates between the bottom surface of the mat base layer and the mounting surface, it is difficult to slide as compared with the case where the depth of the small concave portion is smaller.

  In the anti-skid pile mat of the present invention, it is more preferable that the depth of the small recess is 15 to 40 μm.

  This pile mat is more difficult to slide on a mounting surface such as a floor surface.

  In the anti-skid pile mat of the present invention, the hardness of the elastomer constituting the mat base layer according to the durometer hardness test may be 40 to 50.

  In this case, the hardness of the elastomer constituting the mat base layer in the conventional pile mat was about 60 according to the durometer hardness test. Since the depth of the small concave portions that are uniformly formed is as described above, a pile mat that is more difficult to slide on the mounting surface such as the floor surface is obtained. Moreover, the durability fall etc. by the elastomer which comprises a mat base layer being too soft are prevented substantially.

  The anti-skid pile mat of the present invention is obtained by heating a material obtained by laminating a pile layer on an unvulcanized mat base layer while pressing it with a pressure surface facing in the laminating direction. It can be obtained by vulcanizing into an elastomer and integrating the mat base layer and the pile layer.

  In addition, the anti-skid pile mat of the present invention may have no concave flanges, in particular, groove-shaped flanges, on the bottom surface of the mat base layer, which are wider than the above-mentioned small recesses.

  In this case, the bottom surface of the mat base layer does not have a concave flange, in particular, a groove-shaped flange, in a wider range than each of the small recesses due to the gas remaining between the bottom surface and the pressing surface during pressing.

  Therefore, it is possible to prevent damage from occurring or progressing due to the concave saddle portion in a process such as washing with a centrifugal washing machine or use as a mat.

The manufacturing method of the anti-skid pile mat of the present invention is as follows:
A method for producing the anti-skid pile mat of the present invention,
By heating a laminate of pile layers on an unvulcanized mat base layer while sandwiching it with a pressure surface facing in the stacking direction, the rubber material constituting the mat base layer is vulcanized to become an elastomer, and the mat base. The layer and the pile layer are integrated.
Of the pressurization surfaces, the bottom surface-side pressurization surface opposite to the bottom surface of the mat base layer has a large number of small recesses having a depth of 5 to 50 μm.

  In the process for producing the anti-skid pile mat according to the present invention, the rubber material constituting the mat base layer is vulcanized to proceed with crosslinking, and in the process of elastomerizing the rubber material, the clamping pressure is increased with a low degree of crosslinking. As a state, the gas that may exist between the bottom surface of the mat base layer and the pressing surface on the bottom surface side is released, and then the sandwiching pressure is relatively low with a relatively high degree of crosslinking. desirable.

  In the process of vulcanizing the rubber material constituting the mat base layer to advance the cross-linking and making it into an elastomer, the pressure between the bottom surface of the mat base layer and the bottom surface-side pressure surface is changed to a high state with a low degree of cross-linking. The gas that may be present in between can be released relatively easily, and then the pile is prevented from being over-compressed by setting the pinching pressure to a relatively low state with a relatively high degree of crosslinking.

  As a result, a pile mat is obtained in which the bottom of the mat base layer does not have a wide range of concave ridges, particularly groove-like ridges, than the small concave portions, and the pile standing property is maintained.

  The anti-slide pile mat of the present invention is easy to manufacture, hardly slides on a mounting surface such as a floor, and is excellent in durability. Moreover, according to the manufacturing method of the anti-skid pile mat of the present invention, the anti-skid pile mat of the present invention can be manufactured.

  Embodiments of the present invention will be described with reference to the drawings.

  1 to 3 all relate to an anti-sliding pile mat as an example of an embodiment of the present invention. FIG. 1 is a schematic diagram of pressing and heating a pile cloth, and FIG. 2 is a pressing and heating press. FIG. 3 is a schematic enlarged view of the main part of the bottom surface of the mat base layer, and FIG. 4 is a schematic enlarged cross-sectional view of the main part of the bottom surface of the mat base layer. .

  (1) This anti-skid pile mat M includes an elastomer mat base layer B made of a vulcanized rubber material obtained by vulcanizing NBR (nitrile-butadiene rubber), and a large number of piles P2 on a base fabric P1 (sheet-like substrate). Has a pile layer P implanted therein.

  The pile P2 in the pile layer P has a portion other than the base end portion Pb positioned on the upper side of the base fabric P1, and the base end portion Pb positioned on the lower surface side of the base fabric P1.

  The pile layer P is laminated on the mat base layer B so as to be integrated with each other. On the bottom surface of the mat base layer B, a large number of small recesses R having a depth of about 25 μm and a length of about 0.2 are about 0.5 mm. It is formed evenly (every 0.5 mm). The bottom surface of the mat base layer B does not have a concave flange, particularly a groove-shaped flange, in a wider range than each small recess R.

  The depth of the small recesses R formed uniformly on the bottom surface of the mat base layer B is about 25 μm. The pile mat M is relatively difficult to slide on a mounting surface such as a floor surface as compared with a conventional pile mat having a small concave portion having a depth of about 100 μm. Further, even when water permeates between the bottom surface of the mat base layer B and the mounting surface, it is difficult to slide as compared with the case where the depth of the small concave portion is smaller. Further, by selecting a material so that the mat base layer B (at least its bottom surface) has a slight viscosity, a pile mat that is less active can be obtained.

  The hardness of the elastomer constituting the mat base layer B according to the durometer hardness test is about 45. Therefore, in combination with the above-described configuration of small concave portions that are uniformly formed on the bottom surface of the mat base layer B, the pile mat M is more difficult to slide on the mounting surface such as the floor surface. Moreover, the durability fall etc. by the elastomer which comprises the mat base layer B being too soft are prevented substantially.

  In addition, since the bottom surface of the mat base layer B does not have a wide range of concave ridges, in particular, groove-shaped ridges, than the small concave portions R, the concave ridges can be used in a process such as washing with a centrifugal washing machine or use as a mat. It is prevented that damage is caused or progressed due to the part.

  The vulcanized rubber material is not limited to vulcanized NBR (nitrile-butadiene rubber), and other synthetic rubbers or vulcanized raw rubbers can be used.

  As the sheet-like substrate, various kinds of cloth (woven fabric, nonwoven fabric, etc.) are usually used. In this case, the sheet-like substrate is a base fabric, but it is not always necessary to use a sheet-like material other than the cloth. It is not a thing.

  On the lower surface side of the base fabric P1 in the pile layer P, in order to securely fix the base end portion Pb of each pile P2 to the base fabric P1, a backing (not shown) with a latex material (not limited to this) is provided. Although it is applied, it does not necessarily require backing.

  The small concave portion R formed on the bottom surface of the mat base layer B has a depth of 5 to 50 μm (for example, 5, 10, 15 or 20 μm or more, and can be 50, 40 or 30 μm or less, preferably 10). To 45 μm, more preferably 15 to 40 μm, still more preferably 20 to 30 μm), and a substantially circular, elliptical, or polygonal shape of about 0.1 to 0.8 mm in length and width, and about 0.2 to 1.5 mm. It can be formed uniformly (every time). The peripheral shape of the longitudinal section of the small recess R can be, for example, a substantially parabolic shape, a substantially arc shape, or a substantially folded line shape. It is desirable that the depth of the small recess is substantially constant at the bottom surface of the mat base layer. However, the depth of the small recesses on the bottom surface of the mat base layer is not necessarily required to be constant.

  (2) The pile mat M is manufactured as follows.

  As shown in FIG. 1, a PTFE crude glass fiber cloth CL (a glass fiber cloth impregnated with PTFE, ie, polytetrafluoroethylene and coated with PTFE) on a lower pressure heating press SL, and having a depth of about 100 μm. Many piles P2 are planted on the base fabric P1 and have a large number of small recesses (grains), and backing is applied to the lower surface side of the base fabric P1 with a latex material that fixes the base end portion Pb of each pile P2. The pile cloth P and another PTFE rough glass fiber cloth CH same as those described above are laminated, pressed and heated between the upper and lower pressurizing heating presses SH and SL, and the unevenness on the lower surface side of the base cloth P1 (mainly Unevenness due to the base end portion Pb of the pile P2 is reduced. Of course, it is possible not to employ this step. For example, when the unevenness on the lower surface side of the base fabric P1 is small, this step is not necessarily required.

  Next, as shown in FIG. 2, a PTFE fine glass fiber cloth DL (a glass fiber cloth impregnated with PTFE and coated with PTFE and having a small recess of about 25 μm in depth is provided on a lower pressure heating press SL. And the unvulcanized NBR rubber sheet B is placed thereon, and the pile fabric P after pressurizing and heating and surroundings thereof are placed thereon. An edge rubber E made of unvulcanized NBR is placed, and a PTFE rough glass fiber cloth CH is placed thereon. The edge rubber E has an effect of preventing the pile mat from being deformed (waving or the like) due to continuous use or continuous use and washing, but it is of course possible not to provide the edge rubber E.

  The NRB rubber sheet and the NBR edge rubber E constituting the mat base layer B are vulcanized to become an elastomer by sandwiching these stacks between the upper and lower pressure heating presses SH and SL and heating them by pressurization. The base layer B and the pile layer P are firmly integrated. In this integrated state, the unevenness on the lower surface side of the base fabric P1 due to the base end portion Pb and the like of the pile P2 enters the mat base layer B from the upper side of the mat base layer B.

  In the process of vulcanizing the NRB rubber sheet constituting the mat base layer B to advance the cross-linking and converting the NRB rubber sheet into an elastomer, the pressing force of the upper and lower pressure heating press SH / SL is applied in a state where the degree of cross-linking is low. As a high state, air that may exist between the bottom surface of the mat base layer B and the lower PTFE thin glass fiber cloth DL, which is the bottom surface-side pressure surface, is released, and then the sandwiching is performed with a relatively high degree of crosslinking. Let the pressure be relatively low. The air that may exist between the bottom surface of the mat base layer B and the lower PTFE glass fiber cloth is released relatively easily by setting the sandwiching pressure by the upper / lower pressure heating press SH / SL to be high with the degree of crosslinking being low. After that, the pile P2 constituting the pile layer P is over-compressed by setting the sandwiching pressure by the upper and lower pressure heating presses SH and SL to be relatively low with the degree of crosslinking being relatively high. Is prevented.

  By releasing the press by the upper and lower pressure heating press SH / SL and removing the upper and lower PTFE coarse glass fiber cloth CH and the PTFE thin glass fiber cloth DL, the bottom surface of the mat base layer B has a wider concave shape than each small concave portion R. The anti-skid pile mat M is obtained which does not have a collar portion, in particular, a groove-shaped collar portion and maintains the standing property of the pile P2.

  In this example, after cooling, unnecessary portions of the peripheral rubber E are cut off to obtain the anti-skid pile mat M shown in FIG. In this example, the upper surface of the base fabric P1 of the anti-skid pile mat M and the upper surface of the edge rubber E are substantially the same height.

  It should be noted that the dimensions, number, material, shape, relative arrangement, etc. of the component parts in the description of the above embodiments are limited to the scope of the present invention unless otherwise specified. It is not intended to be limiting, but merely an illustrative example.

It is a schematic diagram which pressurizes and heats a pile cloth. It is a schematic diagram which manufactures a pile mat by vulcanizing an NRB rubber sheet with a pressure heating press. It is a schematic cross section of a slide prevention pile mat. It is a principal part model enlarged view of the bottom face of a mat base layer. It is a principal part schematic expanded sectional view of the bottom face part of a mat base layer.

Explanation of symbols

B Mat base layer, unvulcanized NBR rubber sheet CH PTFE coarse glass fiber cloth CL PTFE coarse glass fiber cloth DL PTFE fine glass fiber cloth E NBR edge rubber, edge rubber M Pile mat P Pile layer, Pile cloth P1 Base cloth P2 Pile Pb Base end R Small recess SL Lower pressure heating press SH Upper pressure heating press

Claims (7)

An elastomeric mat base layer made of vulcanized rubber material;
A pile layer in which a large number of piles are planted on a sheet-like substrate, the base end of the pile being located on the lower surface side of the sheet-like substrate,
A pile mat is formed by laminating a pile layer on a mat base layer, and the two are integrally formed, and a large number of small recesses are uniformly formed on the bottom surface of the mat base layer,
A non-sliding pile mat, wherein the small recess has a depth of 5 to 50 µm.   The anti-skid pile mat according to claim 1, wherein the bottom surface of the mat base layer does not have a concave flange portion wider than each of the small concave portions.   The anti-skid pile mat according to claim 1 or 2, wherein the small recess has a depth of 15 to 40 µm.   The anti-skid pile mat according to claim 1, 2, or 3, wherein the elastomer constituting the mat base layer according to a durometer hardness test has a hardness of 40 to 50.   By heating a laminate of pile layers on an unvulcanized mat base layer while sandwiching it with a pressure surface facing in the stacking direction, the rubber material constituting the mat base layer is vulcanized to become an elastomer, and the mat base. The anti-skid pile mat according to any one of claims 1 to 4, which is obtained by integrating the layer and the pile layer. A method for manufacturing the anti-skid pile mat according to any one of claims 1 to 5,
By heating a laminate of pile layers on an unvulcanized mat base layer while sandwiching it with a pressure surface facing in the stacking direction, the rubber material constituting the mat base layer is vulcanized to become an elastomer, and the mat base. The layer and the pile layer are integrated.
A method for producing a non-sliding pile mat, characterized in that a large number of small concave portions having a depth of 5 to 50 μm are uniformly provided on a bottom-side pressure surface opposite to the bottom surface of the mat base layer among the pressure surfaces.   In the process of vulcanizing the rubber material that constitutes the mat base layer to advance the cross-linking and converting the rubber material into an elastomer, the bottom surface and the bottom surface side of the mat base layer are set with a low degree of cross-linking and a high clamping pressure. The method for producing an anti-skid pile mat according to claim 6, wherein a gas that may exist between the pressurizing surface is allowed to escape, and thereafter, the sandwiching pressure is relatively low while the degree of crosslinking is relatively high.

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